Coated oilfield operational components and methods for protecting and extending the service life of oilfield operational components

ABSTRACT

Coating compositions for coating an oilfield operational component, and related methods, may include in some aspects a coating composition having a trifunctional silane, a silanol, and a filler. The coating composition may be applied to a surface of the oilfield operational component that is configured to be exposed to a fluid. The coating composition may be applied to at least partially cover or coat the surface. The coating composition may be configured to chemically bond with a cured primer composition that includes an epoxy.

PRIORITY CLAIMS

This is a continuation application of U.S. Non-Provisional applicationSer. No. 17/225,543, filed Apr. 8, 2021, titled “COATED OILFIELDOPERATIONAL COMPONENTS AND METHODS FOR PROTECTING AND EXTENDING THESERVICE LIFE OF OILFIELD OPERATIONAL COMPONENTS,” which claims priorityto and the benefit of, under 35 U.S.C. § 119(e), U.S. ProvisionalApplication No. 63/008,035, filed Apr. 10, 2020, titled “COATINGCOMPOSITIONS, COATED OILFIELD OPERATIONAL COMPONENTS, AND RELATEDMETHODS FOR OILFIELD OPERATIONS,” U.S. Provisional Application No.63/008,038, filed Apr. 10, 2020, titled “METHODS FOR PROTECTING OILFIELDOPERATIONAL COMPONENTS FROM DAMAGE FROM FLUID FLOW,” U.S. ProvisionalApplication No. 63/008,042, filed Apr. 10, 2020, titled “COATING ANDMETHODS FOR EXTENDING SERVICE LIFE OF OILFIELD OPERATIONAL COMPONENTS,”U.S. Provisional Application No. 63/008,046, filed Apr. 10, 2020, titled“METHODS FOR PREPARING COATING COMPOSITIONS FOR PROTECTING OILFIELDOPERATIONAL COMPONENTS,” U.S. Provisional Application No. 63/008,049,filed Apr. 10, 2020, titled “METHODS FOR PROVIDING FLEXIBLE AND/ORELASTIC COATINGS ON OILFIELD OPERATIONAL COMPONENTS,” U.S. ProvisionalApplication No. 63/065,542, filed Aug. 14, 2020, titled “COATED OILFIELDOPERATIONAL COMPONENTS AND METHODS FOR PROTECTING AND EXTENDING THESERVICE LIFE OF OILFIELD OPERATIONAL COMPONENTS,” U.S. ProvisionalApplication No. 63/065,545, filed Aug. 14, 2020, titled “METHODS FORPROTECTING OILFIELD OPERATIONAL COMPONENTS FROM DAMAGE FROM FLUID FLOW,”U.S. Provisional Application No. 63/065,565, filed Aug. 14, 2020, titled“COATING AND METHODS FOR EXTENDING SERVICE LIFE OF OILFIELD OPERATIONALCOMPONENTS,” U.S. Provisional Application No. 63/065,577, filed Aug. 14,2020, titled “METHODS FOR PREPARING COATING COMPOSITIONS FOR PROTECTINGOILFIELD OPERATIONAL COMPONENTS,” U.S. Provisional Application No.63/065,591, filed Aug. 14, 2020, titled “METHODS FOR PROVIDING FLEXIBLEAND/OR ELASTIC COATINGS ON OILFIELD OPERATIONAL COMPONENTS,” and U.S.Provisional Application No. 63/198,044, filed Sep. 25, 2020, titled“COATED OILFIELD OPERATIONAL COMPONENTS AND METHODS FOR PROTECTING ANDEXTENDING THE SERVICE LIFE OF OILFIELD OPERATIONAL COMPONENTS,” thedisclosures of all of which are incorporated herein by reference intheir entireties.

FIELD OF THE DISCLOSURE

This disclosure relates to coated oilfield operational components,methods for protecting oilfield operational components, and methods forextending the service life of oilfield operational components.

BACKGROUND

Oilfield operations involve the use of numerous components subjected toharsh use. For example, many components are part of systems that supplyfluid at high flow rates, high pressures, and other usage andenvironmental conditions as will be understood by those in the art. Asan example, fracking operations involve providing fracking fluid at highflow rates and high pressures sufficient to fracture a reservoirformation to allow hydrocarbons to more easily flow from the formationtoward a well for production. For example, typical flow rates may rangefrom about 1,500 to about 4,000 gallons per minute, and typicalpressures may range from about 7,500 to about 15,000 pounds per squareinch. Such high rates of flow and high pressures may result insignificant wear to components associated with the fluid flow. Further,current fracking operations may involve as much as two-to-three timesmore hydraulic horsepower for delivering fracking fluid to a formationthan similar operations performed a decade ago. This increase has oftenresulted in drastically reducing the service life of fluid handlingcomponents of the fracking operation. In addition, fracking fluids maycontain substances or particles that are corrosive and abrasive innature, which increases wear rates of components exposed to the flow offracking fluid. Moreover, components may include internal passages andstructures that increase the effects of the flow of fluid through thecomponent, such as elbows, valves, seals, and pump impellers, which maybe exposed to the effects of cavitation. As a result, componentsassociated with oilfield operations often experience high wear rates,resulting in the need for replacement, which leads to significantexpense associated with replacement costs and downtime. Thus, it may bedesirable to develop systems and methods to extend the service life ofoilfield components. At least some examples described herein may addressone or more of the above-noted possible issues, as well as possiblyothers.

SUMMARY

As referenced above, components associated with oilfield operationsoften experience high wear rates, resulting in the need for replacement,which leads to significant expense associated with replacement costs anddowntime. For example, many components are part of systems that supplyfluid at high flow rates, high pressures, and other usage andenvironmental conditions as will be understood by those in the art. Highflow rates and high pressures may result in significant wear tocomponents associated with the fluid flow. In addition, fracking fluidsmay contain substances or particles that are corrosive and abrasive innature, which increases wear rates of components exposed to the flow offracking fluid. Moreover, components may include internal passages andstructures, such as elbows, valves, seals, and pump impellers, thatincrease the effects of the flow of fluid through the component, andwhich may be exposed to the effects of cavitation.

The present disclosure is generally directed to coatings, oilfieldoperational components, and related methods that may significantlyreduce the wear rates associated with oilfield operational components.In some examples, the coatings and methods may protect the oilfieldoperational components by absorbing and/or dissipating energy offracking fluid as the fracking fluid passes through the components. Insome examples, the coatings and methods may protect the oilfieldoperational components from kinetic energy associated with particles inthe fracking fluid and/or impact energy associated with cavitation ofthe fracking fluid as it flows through the oilfield operationalcomponents.

In a first aspect, an oilfield operational component configured to beused in an oilfield operation may include a component body including asurface positioned to be exposed to fluid flow during an oilfieldoperation. The oilfield operational component may also include a coatingat least partially covering the surface of the component body to enhancewear resistance of the component body, such that the oilfieldoperational component exhibits a comparison factor indicative of anincreased resistance to wear greater than about 2. The coating mayinclude a primer applied to the surface of the component body, and acoating composition at least partially coating the primer. The coatingcomposition may include trifunctional silane, silanol fluid, and filler.The coating composition may be positioned to chemically bond with theprimer.

In another aspect, a method for protecting an oilfield operationalcomponent exposed to flow of an oilfield fluid may include applying aprimer composition to the oilfield operational component. The methodalso may include at least partially curing the primer composition toform a primer layer, such that the primer layer is at least partiallymechanically bonded to the oilfield operational component. The methodfurther may include applying a coating composition to the primer layer,and at least partially curing the coating composition to form a coatinglayer at least partially chemically bonded to the primer layer toenhance wear resistance of the oilfield operational component, such thatthe oilfield operational component exhibits a comparison factorindicative of an increased resistance to wear greater than about 2.

In still a further aspect, a method for increasing a service life of anoilfield operational component positioned to be used in an oilfieldoperation may include at least partially coating an oilfield operationalcomponent positioned to be used in an oilfield operation to obtain afirst coating layer on the oilfield operational component to enhancewear resistance of the oilfield operational component, such that theoilfield operational component exhibits a comparison factor indicativeof an increased resistance to wear greater than about 2. The method alsomay include incorporating the oilfield operational component into anoilfield operation, and exposing the oilfield operational component tofluid flow in the oilfield operation for a first period of time. Themethod further may include at least partially removing at least aportion of the first coating layer from the oilfield operationalcomponent, and at least partially coating the oilfield operationalcomponent to obtain a second coating layer on the oilfield operationalcomponent. One or more of the first coating layer or the second coatinglayer may include trifunctional silane, silanol fluid, and filler. Theone or more of the first coating layer or the second coating layer maybe positioned to reduce a wear-rate of the oilfield operationalcomponent as exposed to fluid flow associated with the oilfieldoperation.

According to yet a further aspect, a coating composition for applying toa surface of an oilfield operational component configured to be exposedto an oilfield fluid may include trifunctional silane, silanol, andfiller. In some examples, silicon in the coating composition may beconfigured to chemically bond with a cured primer composition includingepoxy.

In another aspect, an oilfield operational component configured to beused in an oilfield operation may include the oilfield operationalcomponent and a coating at least partially covering the component. Insome examples, the coating may include a coating composition at leastpartially coating the component, and the coating composition may includetrifunctional silane, silanol fluid, and filler. In some examples, thecoating composition may be configured to chemically bond with a curedepoxy primer.

In still another aspect, a method for applying a coating composition toat least a portion of an oilfield operational component configured to beused in an oilfield operation may include applying a primer compositionto the oilfield operational component and at least partially curing theprimer composition to form an at least partially cured primer layer onat least a portion of the component. The at least partially cured primerlayer may be configured to form a mechanical bond with the at least aportion of the component. The method may further include applying acoating composition to the at least partially cured primer layer. Insome examples, the coating composition may include trifunctional silane,silanol fluid, and filler. The method may further include at leastpartially curing the coating composition such that the coatingcomposition is at least partially chemically bonded to the at leastpartially cured primer.

In yet another aspect, a method for protecting an oilfield operationalcomponent exposed to flow of an oilfield fluid may include applying aprimer composition to the component, and at least partially curing theprimer composition to form a primer layer, such that the primer layer isat least partially mechanically bonded to the component. The method mayfurther include applying a coating composition to the primer layer, andat least partially curing the coating composition to form a coatinglayer at least partially chemically bonded to the primer layer.

According to a further aspect, a method for dissipating energy generatedvia cavitation associated with fluid flow in relation to an oilfieldoperational component exposed to an oilfield fluid may include providinga coating on a least a portion of the component. In some examples, theproviding may include applying a primer composition to the oilfieldoperational component and at least partially curing the primercomposition to form a primer layer, such that the primer layer is atleast partially mechanically bonded to the component. The method mayfurther include applying a coating composition to the primer layer andat least partially curing the coating composition to form a coatinglayer at least partially chemically bonded to the primer layer.

In still a further aspect, a method for dissipating kinetic energyassociated with particles in an oilfield fluid impacting an oilfieldoperational component may include providing a coating layer on a least aportion of the component. In some examples, the providing may includeapplying a primer composition to the oilfield operational component andat least partially curing the primer composition to form a primer layer,such that the primer layer is at least partially mechanically bonded tothe component. The method may further include applying a coatingcomposition to the primer layer and at least partially curing thecoating composition to form a coating layer at least partiallychemically bonded to the primer layer.

In yet another aspect, a method for increasing a service life of anoilfield operational component configured to be used in an oilfieldoperation may include at least partially coating the oilfieldoperational component to obtain a first coating layer on the component.In some examples, the method may further include incorporating theoilfield operational component into an oilfield operation and exposingthe oilfield operational component to fluid flow in the oilfieldoperation for a first period of time. The method may further include atleast partially removing at least a portion of the first coating layerfrom the oilfield operational component and at least partially coatingthe oilfield operational component to obtain a second coating layer onthe component. In some examples, at least one of the first coating layeror the second coating layer may include trifunctional silane, silanolfluid, and filler. The at least one of the first coating layer or thesecond coating layer may be configured to reduce a wear-rate of theoilfield operational component as exposed to fluid flow associated withthe oilfield operation.

According to a further aspect, a method for repairing damage to acoating on an oilfield operational component configured for use in anoilfield operation may include exposing at least a portion of a firstprimer layer associated with a damaged portion of the coating. Themethod may further include applying a primer composition to the at leasta portion of the first primer layer and at least partially curing theprimer composition to obtain a second primer layer bonded to the atleast a portion of the first primer layer. The method may also includeapplying a coating composition to the second primer layer, and at leastpartially curing the coating composition, such that the coatingcomposition at least partially chemically bonds with the second primerlayer.

In still another aspect, a method for repairing damage to a coating onan oilfield operational component configured for use in an oilfieldoperation may include exposing at least a portion of a first primerlayer associated with a damaged portion of the coating and removing atleast a portion of the first primer layer to expose a surface of thecomponent. The method may further include applying a primer compositionto the surface of the oilfield operational component and at leastpartially curing the primer composition to obtain a second primer layerbonded to the surface of the component. The method may also includeapplying a coating composition to the second primer layer and at leastpartially curing the coating composition, such that the coatingcomposition at least partially chemically bonds with the second primerlayer.

In yet a further aspect, a method for replacing at least a portion of afirst coating from an oilfield operational component configured for usein an oilfield operation may include removing at least a portion of thefirst coating from the oilfield operational component and exposing atleast a portion of the component, and cleaning the at least a portion ofthe component. The method may further include applying a primercomposition to the at least a portion of the oilfield operationalcomponent and at least partially curing the primer composition to form aprimer layer at least partially mechanically bonded to the at least aportion of the component. The method may also include applying a coatingcomposition to the primer layer and at least partially curing thecoating composition to form a coating layer at least partiallychemically bonded to the primer layer.

According to a further aspect, a method for preparing a coatingcomposition for application to at least a portion of an oilfieldoperational component to reduce damage induced by flow of an oilfieldfluid may include providing trifunctional silane, providing silanolfluid, and providing filler. The method may further include combiningthe trifunctional silane, the silanol fluid, and the filler. The methodmay further include mixing the trifunctional silane, the silanol fluid,and the filler to obtain the coating composition. In some examples, thecoating composition may be configured to form a coating layer on the atleast a portion of the component, and the coating layer may beconfigured to reduce damage induced by flow of an oilfield fluid.

In yet another aspect, a method for adjusting a hardness of a coatingconfigured to protect at least a portion of an oilfield operationalcomponent configured to be exposed to an oilfield fluid may includepreparing a coating composition. The coating composition may include anamount of trifunctional silane, an amount of silanol fluid, and anamount of filler. The method may further include at least one of: (1)increasing the amount of silanol fluid relative to at least one of theamount of trifunctional silane or the amount of filler to decrease thehardness of the coating; (2) decreasing the amount of silanol fluidrelative to at least one of the amount of trifunctional silane or theamount of filler to increase the hardness of the coating; (3) increasingthe amount of filler relative to at least one of the amount oftrifunctional silane or the amount of silanol fluid to increase thehardness of the coating; or (4) decreasing the amount of filler relativeto at least one of the amount of trifunctional silane or the amount ofsilanol fluid to decrease the hardness of the coating. In some examples,the coating composition may be configured to form a coating layer on theat least a portion of the component, and the coating layer may beconfigured to reduce damage induced by flow of an oilfield fluid.

In still another aspect, a method for adjusting a viscosity of a coatingcomposition for application to at least a portion of an oilfieldoperational component configured to be exposed to an oilfield fluid mayinclude preparing a coating composition. The coating composition mayinclude an amount of trifunctional silane, an amount of silanol fluid,an amount of filler, and an amount of solvent. The method may furtherinclude one of: (1) increasing the amount of solvent relative to atleast one of the amount of trifunctional silane, the amount of silanolfluid, or the amount of filler to reduce the viscosity of the coatingcomposition; or (2) decreasing the amount of solvent relative to atleast one of the amount of trifunctional silane, the amount of silanolfluid, or the amount of filler to increase the viscosity of the coatingcomposition. In some examples, the coating composition may be configuredto form a coating layer on the at least a portion of the component, andthe coating layer may be configured to reduce damage induced by flow ofan oilfield fluid.

According to yet another aspect, a method for providing a flexiblecoating on a surface of an oilfield operational component configured tobe exposed to a flow of an oilfield fluid may include applying a primercomposition to the component. In some examples, the primer compositionmay include epoxy. The method may further include at least partiallycuring the primer composition to obtain a primer layer having a dry filmthickness ranging from about 20 micrometers to about 100 micrometers.The method may also include applying a first coating composition to theprimer layer, and the first coating composition may include at least oneof trifunctional silane, silanol, or filler. The method may furtherinclude at least partially curing the first coating composition toobtain a first coating layer having a dry film thickness ranging fromabout 100 micrometers to about 250 micrometers. In some examples, themethod may further include applying a second coating composition to thefirst coating layer, and the second coating composition may include atleast one of trifunctional silane, silanol, or filler. The method mayfurther include at least partially curing the second coating compositionto obtain a second coating layer having a dry film thickness rangingfrom about 100 micrometers to about 250 micrometers. In some examples,at least one of the primer layer, the first coating layer, or the secondcoating layer may be configured to reduce damage to the oilfieldoperational component from flow of an oilfield fluid.

In yet another aspect, a method for providing an elastic coating on asurface of an oilfield operational component configured to be exposed toa flow of an oilfield fluid may include applying a primer composition tothe component. In some examples, the primer composition may includeepoxy. The method may further include at least partially curing theprimer composition to obtain a primer layer having a dry film thicknessranging from about 20 micrometers to about 100 micrometers. The methodmay also include applying a first coating composition to the primerlayer, and the first coating composition may include at least one oftrifunctional silane, silanol, or filler. The method may further includeat least partially curing the first coating composition to obtain afirst coating layer having a dry film thickness ranging from about 100micrometers to about 250 micrometers. The method may also includeapplying at least one additional coating composition to the firstcoating layer. The at least one additional coating composition mayinclude at least one of trifunctional silane, silanol, or filler. Themethod may further include at least partially curing the at least oneadditional coating composition to obtain at least one additional coatinglayer. In some examples, the total dry film thickness of the firstcoating layer and the at least one additional coating layer may rangefrom about 500 micrometers to about 1000 micrometers. In some examples,at least one of the primer layer, the first coating layer, or the atleast one additional coating layer may be configured to reduce damage tothe oilfield operational component from flow of an oilfield fluid.

Still other aspects, examples, and advantages of these exemplary aspectsand embodiments, are discussed in more detail below. It is to beunderstood that both the foregoing information and the followingdetailed description are merely illustrative examples of various aspectsand embodiments, and are intended to provide an overview or frameworkfor understanding the nature and character of the claimed aspects andembodiments. Accordingly, these and other objects, along with advantagesand features of the present disclosure herein disclosed, may becomeapparent through reference to the following description and theaccompanying drawings. Furthermore, it is to be understood that thefeatures of the various embodiments described herein are not mutuallyexclusive and may exist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the embodiments of the present disclosure, areincorporated in and constitute a part of this specification, illustrateembodiments of the present disclosure, and together with the detaileddescription, serve to explain principles of the embodiments discussedherein. No attempt is made to show structural details of this disclosurein more detail than may be necessary for a fundamental understanding ofthe exemplary embodiments discussed herein and the various ways in whichthey may be practiced. According to common practice, the variousfeatures of the drawings discussed below are not necessarily drawn toscale. Dimensions of various features and elements in the drawings maybe expanded or reduced to more clearly illustrate the embodiments of thedisclosure.

FIG. 1 is a schematic top view of an example oilfield operationincluding an example fracturing system including a partial section viewof schematically-depicted example oilfield component having an internalsurface at least partially coated by an example primer layer and examplecoating layers according to the disclosure.

FIG. 2A is a schematic perspective view of an example fluid end, whichmay be incorporated into a fracturing system according to thedisclosure.

FIG. 2B is a schematic perspective view showing an example internalportion of a fluid end, such as the fluid end shown in FIG. 2A accordingto the disclosure.

FIG. 2C is a schematic perspective view of an example flow ironcomponent, which may be associated with a fluid transporting portion ofan oilfield operation, such as a fracturing system according to thedisclosure.

FIG. 2D is a schematic perspective view of an example fracturing or fracstack, which may be associated with a fluid transporting portion of anoilfield operation, such as a fracturing system according to thedisclosure.

FIG. 3 is a partial cross-section schematic representation of an exampleflow iron component having internal surfaces at least partially coatedwith a primer layer and coating layers and showing an example fluidpassing through the oilfield operational component according to thedisclosure.

FIG. 4 is a partial cross-section schematic representation of an exampleflow iron component having an internal surface at least partially coatedwith a primer layer and coating layers and showing an example fluid flowdirected at the internal surface and deflecting off the internal surfaceof the flow iron component according to the disclosure.

FIG. 5 is a schematic perspective view showing an uncoated portion of anoilfield component, a primer layer, and a coating layer on the primerlayer according to the disclosure.

FIG. 6 is a schematic perspective view showing a primer layer, a firstcoating layer on the primer layer, a second coating layer on the firstcoating layer, and a third coating layer on the second coating layeraccording to the disclosure.

FIG. 7 is a schematic perspective view of example particles contactingan example coating layer according to the disclosure.

FIG. 8 is a schematic illustration of an example coating assemblyconfigured to apply a coating composition to oilfield operationalcomponents according to the disclosure.

FIGS. 9A, 9B, 9C, are 9D are schematic representations of a testingarrangement including a test sample exposed to a test fluid flow at anincluded angle β relative to the test sample according to thedisclosure.

FIG. 10 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples, coated test samples, and testsamples coated with a chemical-resistant coating, simulating a goat headcomponent exposed to fluid flow at different included angles accordingto the disclosure.

FIG. 11 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinga fluid end exposed to fluid flow at different included angles accordingto the disclosure.

FIG. 12 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatingfrac iron exposed to fluid flow at different included angles accordingto the disclosure.

FIG. 13 is a graph of cumulative mass loss (grams (g)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at zerodegrees according to the disclosure.

FIG. 14 is a graph of cumulative mass loss (grams (g)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at 30degrees according to the disclosure.

FIG. 15 is a graph of cumulative mass loss (grams (g)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at 45degrees according to the disclosure.

FIG. 16 is a graph of cumulative mass loss (grams (g)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at 60degrees according to the disclosure.

FIG. 17 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at zerodegrees according to the disclosure.

FIG. 18 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at 30degrees according to the disclosure.

FIG. 19 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at 45degrees according to the disclosure.

FIG. 20 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at 60degrees according to the disclosure.

FIG. 21 is a bar graph showing estimated hours to 0.014 inches of weardepth for bare samples and coated samples simulating goat heads, fluidends, and frac iron exposed to fluid flow at different included anglesand for each of two sand sizes (270 mesh and larger 100 mesh) accordingto the disclosure.

FIG. 22 is a bar graph showing estimated hours to 0.014 inches of weardepth for bare samples, samples having 0.014 inches of depth of coating(“coated”), samples having 0.028 inches of depth of coating(“thick-coated”), and samples coated with a chemical-resistant coating(“chem. resistant”), simulating goat heads exposed to fluid flow at zeroand 30 degrees and for each of two sand sizes (270 mesh and larger 100mesh) according to the disclosure.

DETAILED DESCRIPTION

Referring now to the drawings in which like numerals indicate like partsthroughout the several views, the following description is provided asan enabling teaching of exemplary embodiments, and those skilled in therelevant art will recognize that many changes may be made to theembodiments described. It also will be apparent that some of the desiredbenefits of the embodiments described may be obtained by selecting someof the features of the embodiments without utilizing other features.Accordingly, those skilled in the art will recognize that manymodifications and adaptations to the embodiments described are possibleand may even be desirable in certain circumstances, and are a part ofthe disclosure. Thus, the following description is provided asillustrative of the principles of the embodiments and not in limitationthereof.

The phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. As used herein, theterm “plurality” refers to two or more items or components. The terms“comprising,” “including,” “carrying,” “having,” “containing,” and“involving,” whether in the written description or the claims and thelike, are open-ended terms, i.e., to mean “including but not limitedto.” Thus, the use of such terms is meant to encompass the items listedthereafter, and equivalents thereof, as well as additional items. Onlythe transitional phrases “consisting of” and “consisting essentiallyof,” are closed or semi-closed transitional phrases, respectively, withrespect to any claims. Use of ordinal terms such as “first,” “second,”“third,” and the like in the claims to modify a claim element does notby itself connote any priority, precedence, or order of one claimelement over another or the temporal order in which acts of a method areperformed, but are used merely as labels to distinguish one claimelement having a certain name from another element having a same name(but for use of the ordinal term) to distinguish claim elements.

Generally, this disclosure outlines coating compositions, coatedcomponents, and related methods, and in particular, coatingcompositions, coated components, and related methods for protectingcomponents from wear related to fluid flow in oilfield operations.Oilfield operations may include any on-site activities related to oilexploration, drilling, completions, stimulation, and/or production, forexample, associated with the petroleum industry. In some instances,oilfield operations also may include logistical activities of suchoperations including pipelines and pipeline parts such as pipelinepumps, elbows, and various pipeline segments, for example. Fluid flow inoilfield operations may include the flow of any oilfield fluid includingany fluids or fluid-like materials associated with any oilfieldoperation, including, but not limited to, fracking fluid or any fluidrelated to a hydraulic fracturing operation, drilling fluid, productionfluid, and/or reservoir fluid. As an example, fracturing is an oilfieldoperation that stimulates production of hydrocarbons, such that thehydrocarbons may more easily or readily flow from a subterranean ofsubsurface formation to a borehole of a well. Although many examplesdiscussed in this disclosure are explained in relation to fracturingequipment, fracturing components, and related methods, otheroilfield-related operations, components, and methods are contemplated.

FIG. 1 is a schematic top view of an example oilfield operation 10including an example fracturing system 12 (e.g., a hydraulic fracturingsystem), and showing a partial section view of a schematically-depictedexample oilfield component 14 including a component body 16 having aninternal surface at least partially coated by an example primer layer 18and example coating layers 20. In some examples, the fracturing system12 may be configured to fracture a formation by pumping a fracking fluidinto a well at high pressure and high flow rates. A fracking fluid mayinclude, for example, water, proppants, and/or other additives, such asthickening agents and/or gels. For example, proppants may include grainsof sand, ceramic beads or spheres, shells, and/or other particulates,and may be added to the fracking fluid, along with gelling agents tocreate a slurry. The slurry may be forced via one or more pumps from thesurface into the subterranean formation via a borehole at rates fasterthan may be accepted by the existing pores, fractures, faults, or otherspaces within the formation. As a result, pressure builds rapidly to thepoint where the formation fails and begins to fracture. By continuing topump the fracking fluid into the formation, existing fractures in theformation are caused to expand and extend in directions farther awayfrom a well bore, thereby creating flow paths to the well. The proppantsmay serve to prevent the expanded fractures from closing when pumping ofthe fracking fluid is ceased or may reduce the extent to which theexpanded fractures contract when pumping of the fracking fluid isceased. Once the well is fractured, large quantities of the injectedfracking fluid are allowed to flow out of the well, and the water andany proppants not remaining in the expanded fractures may be separatedfrom hydrocarbons produced by the well to protect downstream equipmentfrom damage and corrosion. In some instances, the production stream maybe processed to neutralize corrosive agents in the production streamresulting from the fracturing process.

In the example shown in FIG. 1, the fracturing system 12 includes aplurality of water tanks 22 for supplying water for a fracking fluid, achemical tank 24 for supplying gels or agents for adding to the frackingfluid, and a plurality of proppant tanks 26 (e.g., sand tanks) forsupplying proppants for the fracking fluid. The example fracturingsystem 12 shown also includes a hydration unit 28 for mixing water fromthe water tanks 22 and gels and/or agents from the chemical tank 24 toform a mixture, for example, gelled water. The example shown alsoincludes a blender 30, which receives the mixture from the hydrationunit 28 and proppants via conveyers 32 from the proppant tanks 26. Theblender 30 may mix the mixture and the proppants into a slurry to serveas fracking fluid for the fracturing system 12. Once combined, theslurry may be discharged through low-pressure hoses 34, which convey theslurry into two or more low-pressure lines 36 in a frac manifold 38. Inthe example shown, the low-pressure lines 36 in the frac manifold 38feed the slurry to a plurality of pumps 40 through low-pressure suctionhoses 42.

The pumps 40 may be driven by motors (e.g., internal combustion enginesand/or electric motors) and discharge the slurry (e.g., the frackingfluid including the water, agents, gels, and/or proppants) at highpressure and/or a high flow rate through individual high-pressuredischarge lines 44 into two or more high-pressure flow lines 46,sometimes referred to as “missiles,” on the frac manifold 38. The flowfrom the flow lines 46 is combined at the frac manifold 38, and one ormore of the flow lines 46 provide flow communication with a manifoldassembly 48, sometimes referred to as a “goat head.” The manifoldassembly 48 delivers the slurry into a wellhead manifold 50, sometimesreferred to as a “zipper manifold” or a “frac manifold.” The wellheadmanifold 50 may be configured to selectively divert the slurry to, forexample, one or more well heads 52 via operation of one or more valves.Once the fracturing process is ceased or completed, flow returning fromthe fractured formation discharges into a flowback manifold 54, and thereturned flow may be collected in one or more flowback tanks 56.

As schematically depicted in FIG. 1, one or more of the components ofthe fracturing system 12 may be configured to be portable, so that thefracturing system 12 may be transported to a well site, quicklyassembled, operated for a relatively short period of time, at leastpartially disassembled, and transported to another location of anotherwell site for use. For example, the components may be carried bytrailers and/or incorporated into trucks, so that they may be easilytransported between well sites.

At least some of the components of the fracturing system 12 may bereferred to collectively as “frac iron.” Such components may include,for example, straight sections of steel pipe and pipe joints, variousfittings, such as tee-fittings, cross-fittings, lateral-fittings, andwye-fittings, which may provide junctions at which flow is split orcombined, and flow line components including fittings configured toalter the course of a flow line, such as elbows and swivel joints. Insome examples, the frac iron may be configured to convey fracking fluidunder high pressure and/or high flow rates. In some examples, the fraciron may incorporate therein gauges, other monitoring equipment, and/orcontrol devices, such as shut-off valves, plug valves, check valves,throttle valves, pressure-release valves, butterfly valves, and/or chokevalves.

Because some components of a fracturing system 12 may be subjected tohigh pressures and/or high flow rates, and because fracking fluid maycontain substances having abrasive and/or corrosive characteristics,such components of the fracturing systems 12 may exhibit high wear ratesand/or high failure rates. At least some examples of coatings, coatedcomponents, and/or related methods may be directed to reducing such wearrates and/or failure rates.

As shown in FIG. 1, the example oilfield component 14 has a componentbody 16 having an internal surface at least partially coated by anexample primer layer 18 and example coating layers 20 to protect theoilfield operational component 14 from wear induced by the flow of fluidthrough the oilfield operational component 14, such that at least insome examples, the wear rate and/or the failure rate of the oilfieldoperational component 14 may be reduced, and/or the service life of theoilfield operational component 14 may be extended, for example, asexplained herein. In some examples, the primer layer 18 may be omittedor there may be more than one primer layer 18, and in some examples,there may be fewer or more coating layers 20 (e.g., one or two coatinglayers 20, or four or more coating layers 20). In examples having morethan one primer layer 18, the primer layers 18 may be the same materialor different materials, and/or the primer layers 18 may have the samethickness or different thicknesses. In examples having more than onecoating layer 20, the coating layers 20 may be the same material ordifferent materials, and/or the coating layers 20 may have the samethickness or different thicknesses.

FIG. 2A is a schematic perspective view of component 14 in the form ofan example fluid end 58, which may be incorporated into a fracturingsystem, such as the example fracturing system 12 shown in FIG. 1. In theexample shown in FIG. 2A, the fluid end 58 includes a fluid end block60, which may typically be formed from steel (e.g., stainless steel) andmay be machined to provide internal passages and/or may be formed withinternal passages (e.g., via casting). In some examples, the fluid end58 may be connected to a power end of a reciprocating pump having aplurality of reciprocating plungers that cyclically extend at leastpartially into and at least partially retract from passages in the fluidend 58. During retraction, low pressure fluid (e.g., fracking fluid) isdrawn into the fluid end 58, for example, via low-pressure suction hoses42 (FIG. 1), and during extension, high pressure fluid is dischargedfrom the fluid end 58, for example, via high-pressure discharge lines 44(FIG. 1).

For example, FIG. 2B is a schematic perspective view of an exampleinternal portion 62 of the fluid end 58, such as the fluid end 58 shownin FIG. 2A. (FIG. 2A shows a single portion 62, but a fluid end mayinclude more internal portions.) The example portion 62 includes anintake port 64 configured to facilitate intake of fluid into the fluidend 58 and an exhaust port 66 configured to facilitate discharge offluid from the fluid end 58. The example portion 62 also includes acylinder 68 configured to receive a reciprocating plunger of a power endof a pump. As the reciprocating plunger at least partially retracts fromthe cylinder 68, fluid is drawn into the fluid end 58 via the intakeport 64. Valves (not shown) in the fluid end 58 between the intake port64 and the exhaust port 66 operate cyclically as the plungerreciprocates to facilitate the intake and discharge of the fluid fromthe fluid end 58. In this example manner, the fluid end 58 draws influid at low pressure and discharges the fluid at high pressure. In someexamples, the fluid end 58 may include a plurality of sets of intakeports, cylinders, and exhaust ports to pump fluid at higher pressuresand/or flow rates. Due to the high pressures and high volumes to whichthe fluid end 58 is exposed, the fluid end block 60, valves, valveseats, and/or packing sets of the fluid end 58 may be subject to highwear rates and/or high failure rates.

FIG. 2C is a schematic perspective view of an example flow ironcomponent 70, which may be associated with a fluid transporting portionof an oilfield operation, such as a fracturing system. As shown in FIG.2C, the example flow iron component 70 includes a tubular portion 72 inwhich an internal passage 74 is defined by internal surfaces 76. Theexample tubular portion 72 shown in FIG. 2C forms a U-shape. Tubularportions having other shapes are contemplated, such as straight andninety-degree bends, obtuse bends, and acute bends. As shown in FIG. 2C,the example flow iron component 70 also includes a first coupler 78 at afirst end of the tubular portion 72 and a second coupler 80 at a second,opposite end of the tubular portion 72. The first and second couplers 78and 80 may be configured to couple the flow iron component 70 to othercomponents of the oilfield operation (e.g., a fracturing system), forexample, via complimentary couplers of the other components.

FIG. 2D is a schematic perspective view of an example frac stack 82,which may be associated with a fluid transporting portion of an oilfieldoperation, such as the example fracturing system 12. The example fracstack 82 shown in FIG. 2D includes an example goat head 84, an exampleupper master valve 86, an example lower master valve 88, and examplegate valves 90. The example frac stack 82 may generally correspond tothe manifold assembly 48 shown in FIG. 1. In some examples, the goathead 84 may be configured to serve as a high-pressure flow cross in flowcommunication with one or more well heads (e.g., similar to well heads52 shown in FIG. 1). In some examples, for example as shown, the goathead 84 may include a plurality of couplers 92 configured to connectflow iron to one or more well heads, so that fracking fluid may besupplied to the one or more well heads. In some examples, the uppermaster valve 86 and/or the lower master valve 88 may be configured to atleast partially control the flow of fracking fluid to the one or morewell heads during a fracking operation. One or more of the upper mastervalve 86 or the lower master valve 88 may be closed to shut in the wellheads, for example, during an emergency situation. In some examples, theupper master valve 86 and/or the lower master valve 88 may be configuredto be manually operated and/or remotely operated. In some examples, oneor more of the gate valves 90 may be configured to at least partiallycontrol flow of fracking fluid through the frac stack 82, for example,to control fluid flow back and/or during wireline pump down operations.

FIG. 3 is a partial cross-section schematic representation of an exampleflow iron component 94 having internal surfaces 96 at least partiallycoated with a primer layer 98 and one or more coating layers 100 (e.g.,coating layers 100 a, 100 b, and 100 c, as shown) and showing an examplefluid 102 passing through the flow iron component 94. The example flowiron component 94 may correspond to any flow iron component used in anoilfield operation, such as, for example, a fracking operation that maybe performed by a fracking system, such as the example fracturing system12 shown FIG. 1. Although the example flow iron component 94 shown inFIG. 3 includes an elbow, other configurations of flow iron componentare contemplated, such as any fluid handling component associated withan oilfield operation.

The internal surface 96 of the example flow iron component 94 shown inFIG. 3 is at least partially coated by the example primer layer 98 andthe example coating layers 100 a, 100 b, and 100 c to protect the flowiron component 94 from wear induced by the flow of an example fluid 102through the flow iron component 94, such that at least in some examples,the wear rate and/or the failure rate of the flow iron component 94 maybe reduced, and/or the service life of the flow iron component 94 may beextended, for example, as explained herein. In the example schematicallyshown in FIG. 3, the fluid 102 is an example fracking fluid including,for example, water, one or more agents and/or gels, and proppants 104,which may include grains of sand, ceramic beads or spheres, shells,and/or other similar particulates. In some examples, the primer layer 98may be omitted or there may be more than one primer layer 98. Inexamples having more than one primer layer 98, the primer layers 98 maybe the same material or different materials, and/or the primer layers 98may have the same thickness or different thicknesses. In some examples,there may be fewer or more coating layers 100. In examples having morethan one coating layer 100, the coating layers 100 may be the samematerial or different materials, and/or the coating layers 100 may havethe same thickness or different thicknesses.

As explained in more detail herein, in some examples, one or more of thecoating layers 100 may be formed from a coating composition, and thecoating composition may include trifunctional silane, silanol, and/orfiller. In examples including one or more primer layers 98, the primerlayer may be formed from a primer composition, which may include epoxy.In some examples, one or more of the primer composition or the coatingcomposition may be at least partially cured to form a dry film layer. Insome examples, the primer layer may be at least partially cured and forma mechanical bond with at least a portion of the component. In someexamples, the coating composition may be configured to chemically bondwith a cured primer composition including epoxy.

FIG. 4 is a partial cross-section schematic representation of an exampleflow iron component 106 having an internal surface 108 at leastpartially coated with a primer layer 98 and one or more coating layers100 (e.g., coating layers 100 a, 100 b, and 100 c, as shown) and showingan example fluid flow 110 directed at the internal surface 108 anddeflecting off the internal surface 108 of the flow iron component 106.As shown in FIG. 4, the fluid flow 110 is an example fracking fluidincluding, for example, water, one or more agents and/or gels, andproppants 112, which may include grains of sand, ceramic beads orspheres, shells, and/or other similar particulates. As schematicallydepicted in FIG. 4, one or more of the coating layers 100 may beconfigured to compress and/or flex in response to the fluid flow 110impacting the coating layers 100. As explained in more detail herein,the compression and/or flexing of one or more of the coating layers mayresult in the one or more coating layers 100 absorbing and/ordissipating energy associated with the fluid flow 110, which in at leastsome examples, may serve to protect the internal surface 108 of the flowiron component 106. In some examples, the energy associated with thefluid flow 106 may include heat energy and/or kinetic energy, which mayresult from, for example, the temperature of the fluid flow 110, theflow rate of the fluid flow 110, impact of the proppants 104 against theone or more coating layers 100, and/or impacts generated by cavitationof the fluid flow 110, as well as other possible forms of energyassociated with the fluid flow. In at least some examples, the one ormore coating layers 100 may also serve to reduce or eliminate anycorrosive effects associated with the fluid flow 110.

FIG. 5 is a schematic perspective view showing an uncoated portion of anoilfield operational component, such as a flow iron component 106, aprimer layer 98 covering a portion of the flow iron component 106, and acoating layer 100 covering a portion of the primer layer 98 according tothe disclosure. FIG. 6 is a schematic perspective view showing a primerlayer 98 covering a portion of an oilfield operational component, suchas a flow iron component 106, a first coating layer 100 a covering aportion of the primer layer 98, a second coating layer 100 b covering aportion of the first coating layer 100 a, and a third coating layer 100c covering a portion of the second coating layer 100 b according to thedisclosure.

For example, a primer composition may be applied to the flow ironcomponent 106, for example, as described herein, and may be at leastpartially cured (e.g., fully cured) to form the primer layer 98 bondedto the flow iron component 106 (e.g., forming a mechanical bond, achemical bond, or a combination of a mechanical bond and a chemicalbond). Thereafter, the coating composition may be applied to the atleast partially cured primer layer 98, for example, as described herein,and may be at least partially cured (e.g., fully cured) to form thefirst coating layer 100 a bonded to the primer layer 98 (e.g., forming amechanical bond, a chemical bond, or a combination of a mechanical bondand a chemical bond with the primer layer 98). Thereafter, the coatingcomposition may be applied to the at least partially cured first coatinglayer 100 a, for example, as described herein, and may be at leastpartially cured (e.g., fully cured) to form the second coating layer 100b (e.g., forming a mechanical bond, a chemical bond, or a combination ofa mechanical bond and a chemical bond with the first coating layer 100a). Thereafter, the coating composition may be applied to the at leastpartially cured second coating layer 100 b, for example, as describedherein, and may be at least partially cured (e.g., fully cured) to formthe third coating layer 100 c (e.g., forming a mechanical bond, achemical bond, or a combination of a mechanical bond and a chemical bondwith the second coating layer 100 b). It is contemplated that in someembodiments the primer layer 98 may be omitted, and in other embodimentsmore than a single primer layer may be applied and at least partiallycured as will be understood by those skilled in the art. It iscontemplated that in some embodiments that fewer than three coatinglayers 100 may be applied and at least partially cured, and in otherembodiments, more than three coating layers 100 may be applied and atleast partially cured.

FIG. 7 is a schematic perspective view of example particles such asproppants 104 contacting an example coating layer 100 according to thedisclosure. In some embodiments, the one or more coating layers 100(and/or the one or more primer layers 98) may at least partiallyelastically deform, for example, to form elastic and/or resilientdepressions 114 upon impact of particles such as proppants 104. Forexample, the one or more primer layers 98 and/or the one or more coatinglayers 100 may dissipate kinetic energy associated with the impact ofparticles as thermal energy and thereby inhibit particles before theyreach the substrate, so that the impacting particles may not erode,chip, and/or deform the substrate (e.g., the oilfield operationalcomponent). Because, in at least some examples, the one or more coatinglayers 100 may absorb vibrational as well as kinetic energy, secondaryvibrations that may be induced in the coating layer(s) 100 by impactingparticles may be inhibited, which may prevent transmission of thesecondary vibrations to the substrate. In addition, in at least someexamples, the one or more coating layers 100 may be flexible, and thus,the one or more coating layers may not impede flexing of the componentor impose additional mechanical stresses on a component that flexes aswill be understood by those skilled in the art.

In at least some examples, the one or more coating layers 100 may beuseful in protecting any fluid handling part from degradation by thesurrounding environment. For example, the one or more coating layers maybe configured to protect a fluid-handling part from erosion caused byparticle impact, impingement, or cavitation. Erosion by particle impactmay be caused by particles (e.g., proppants) entrained in the fluidflow, which may be either a gas flow or a liquid flow. Impingement maybe an accelerated form of corrosion associated with bubbles entrained inthe fluid flow. Cavitation may occur in incompressible fluids, such aswater, and cavitation may involve the formation of bubbles caused byboiling of the fluid at a low pressure, along with the sudden collapseof the bubbles. The formation and collapse of a single such bubble maybe considered a cavitation event. Thus, in some instances, more than oneof the mechanisms of particle impact, impingement, and/or cavitation maysubstantially simultaneously act on a fluid handling part, such as aflow iron component.

In at least some examples of coating composition, the coatingcomposition may include trifunctional silane. In at least some suchexamples, the trifunctional silane may include an acetoxy silane, aketoximino silane, an enoxy silane, an amine silane, an alkoxy silane,and/or an alkenyl silane. In at least some such examples, thetrifunctional silane may include ethyl triacetoxysilane and/or vinyltriacetoxysilane. In some such examples, the trifunctional silane mayinclude methyl tris (methyl-ethyl-ketoximino) silane and/or vinyl tris(methyl-ethyl-ketoximino) silane.

In at least some examples of coating composition, the coatingcomposition may include silanol, such as silanol fluid. In at least somesuch examples, the silanol fluid may include a polydialkylated siloxane,such as polydimethylsiloxane. For example, the silanol fluid may includea hydroxyl-terminated polydimethylsiloxane. In some such examples, thesilanol fluid may have a kinematic viscosity ranging from about 90centistokes to about 150,000 centistokes (e.g., from about 100centistokes to about 130,000 centistokes, from about 200 centistokes toabout 100,000 centistokes, from about 300 centistokes to about 90,000centistokes, from about 400 centistokes to about 85,000 centistokes, orfrom about 500 centistokes to about 70,000 centistokes,). For a silanolfluid including linear chains and/or a unimodal molecular weightdistribution, the silanol fluid may have a weight average molecularweight (MW) ranging from about 4,000 grams/mole (g/mol) to about 150,000g/mol (e.g., from about 8,000 grams/mole to about 140,000 g/mol, fromabout 12,000 grams/mole to about 120,000 g/mol, or from about 10,000grams/mole to about 100,000 g/mol) and/or a range of hydroxyl contentranging from about 0.8 wt % to about 0.02 wt % (e.g., from about 0.7 wt% to about 0.05 wt %, from about 0.6 wt % to about 0.10 wt %, or fromabout 0.5 wt % to about 0.15 wt %). In some examples, the silanol fluidmay have a kinematic viscosity ranging from about 700 centistokes toabout 130,000 centistokes (e.g., with linear chains and a unimodaldistribution), a viscosity of about of 700 centistokes (e.g., from about500 centistokes to about 900 centistokes, or from about 600 centistokesto about 800 centistokes), a corresponding to MW about 18,000 g/mol, anda hydroxyl content of about 0.2 wt. %. In some examples, the silanolfluid may have a kinematic viscosity ranging from about 2,000centistokes to about 130,000 centistokes (e.g., with linear chains and aunimodal distribution), a viscosity of about 2,000 centistokes (e.g.,from about 1,500 centistokes to about 2,500 centistokes, or from about1,750 centistokes to about 2,250 centistokes), a corresponding MW ofabout 35,000 g/mol, and a hydroxyl content of approximately 0.09 wt. %.In some examples, the silanol fluid may have a kinematic viscosityranging from about 40,000 centistokes to about 130,000 centistokes(e.g., with linear chains and a unimodal distribution), a viscosity of40,000 centistokes (e.g., from about 35,000 centistokes to about 45,000centistokes, or from about 37,500 centistokes to about 42,500centistokes), a corresponding MW of about 85,000 g/mol, and a hydroxylcontent of about 0.04 wt. %.

In at least some examples, the coating composition may include one ormore fillers. In at least some such examples, the one or more fillersmay include fumed silica and/or reinforcing agents, such as, forexample, glass fiber, mica, wollastonite, kaolin, and/or otherphylosilicates. In at least some examples including fumed silica, thefumed silica may be treated with an agent before or during addition tothe remainder of the coating composition. Examples of treatment agentsinclude hexamethylenedisilazane, divinyltetramethylenedisilazane,chlorosilane, and/or polydimethylsiloxane. In at least some examples,the one or more fillers may include particles having a relatively highaspect ratio and/or a relatively high shape factor. For example, thefiller may include mica, and mica platelets having a high square root ofarea-to-thickness ratio may be included in the coating composition. Inat least some examples, the filler may include glass fibers, and glassfibers having a high length-to-diameter ratio may be included in thecoating composition. In some examples, the filler may have an aspectratio of at least 2, a shape factor of at least 2, or alength-to-diameter ratio of at least 2. In at least some examples, morethan one type of filler may be included in the coating composition. Forexample, both fumed silica and mica may be included in the coatingcomposition.

In at least some examples, the coating composition may include acatalyst, for example, to speed curing of the coating composition. In atleast some such examples, more than a single catalyst may beincorporated into the coating composition. In at least some examplesincluding a catalyst, the coating composition may include a tincatalyst, such as, for example, dibutyl tin dilaurate.

At least some examples of the coating composition may include one ormore pigment agents. Pigment agents may be used to improve an aestheticappearance of a coated fluid handling component and/or protect a fluidhandling component from visible and/or ultraviolet light. In at leastsome examples, the coating composition may include one or more solvents,such as, for example, xylene and/or mineral spirits. Solvents may serveadjust (e.g., reduce) the viscosity of the coating composition, forexample, in order to facilitate mixing and/or application of the coatingcomposition to a fluid handling component. For example, one or moresolvents may be included in the coating composition to facilitateapplication of the coating composition to a fluid handling component viaspraying using a sprayer.

According to at least some examples, coating layers that are relativelysofter and/or coating layers that have a relatively lower modulus may berelatively more effective at protecting fluid handling components, suchas flow iron components, from damage and/or erosion by particle impact,impingement, and/or cavitation as compared to relatively harder coatinglayers and coating layers having a relatively higher modulus. In atleast some examples, the coating compositions may be tailored and/oradjusted to form coating layers tailored for use in certainenvironments. For example, the relative hardness of a coating layer maybe adjusted.

In at least some examples, a method for adjusting a hardness of acoating configured to protect at least a portion of component configuredto be exposed to a fluid such as a fracking fluid may include preparinga coating composition. The coating composition may include, for example,an amount of trifunctional silane, an amount of silanol fluid, and anamount of filler. The method for adjusting the hardness of the coatinglayer may include at least one of: (1) increasing the amount of silanolfluid relative to at least one of the amount of trifunctional silane orthe amount of filler to decrease the hardness of the coating, (2)decreasing the amount of silanol fluid relative to at least one of theamount of trifunctional silane or the amount of filler to increase thehardness of the coating, (3) increasing the amount of filler relative toat least one of the amount of trifunctional silane or the amount ofsilanol fluid to increase the hardness of the coating, or (4) decreasingthe amount of filler relative to at least one of the amount oftrifunctional silane or the amount of silanol fluid to decrease thehardness of the coating.

In at least some examples, the viscosity of the coating composition maybe tailored and/or adjusted, for example, by changing the fraction ofsolvent (if any) included in the coating composition. For example, arelatively higher viscosity coating composition may be desirable whenthe coating composition is intended to be is manually applied, forexample, by spreading the coating composition with a brush and/orspatula. A relatively lower viscosity coating composition may bedesirable when the coating composition is intended to be applied, forexample, via spraying onto a fluid handling part, such as a flow ironcomponent.

In at least some examples, a method for adjusting the viscosity of acoating composition for application to at least a portion of an oilfieldoperational component configured to be exposed to a fluid such as afracking fluid may include preparing a coating composition. The coatingcomposition may include an amount of trifunctional silane, an amount ofsilanol fluid, an amount of filler, and an amount of solvent. The methodfor adjusting the viscosity of a coating composition may include one of:(1) increasing the amount of solvent relative to at least one of theamount of trifunctional silane, the amount of silanol fluid, or theamount of filler to reduce the viscosity of the coating composition, or(2) decreasing the amount of solvent relative to at least one of theamount of trifunctional silane, the amount of silanol fluid, or theamount of filler to increase the viscosity of the coating composition.

In at least some examples of the coating composition includingtrifunctional silane, silanol fluid, and filler, the trifunctionalsilane may comprise from about 0.01 wt % to about 20 wt % of the coatingcomposition on the basis of non-solvent components, the silanol fluidmay comprise from about 40 wt % to about 99 wt % of the coatingcomposition on the basis of non-solvent components, and the filler(e.g., fumed silica) may comprise from about 0.01 wt % to about 25 wt %of the coating composition on the basis of non-solvent components. Insome examples, the coating composition may also include one or morecatalysts that comprise about 0.01 wt % to about 5 wt % of the coatingcomposition on the basis of non-solvent components, and/or one or morepigments that comprise about 0.01 wt % to about 10 wt % of the coatingcomposition on the basis of non-solvent components.

In at least some examples, the coating composition may include one ormore solvents. For example, the coating composition may include fromabout 10 parts to about 300 parts by weight of xylene per 100 parts byweight of the non-solvent components of the coating composition toproduce a solvent-inclusive coating composition, which may be applied insome examples via spraying onto a component. For example, about 100parts by weight (e.g., 108 parts by weight) of xylene may be added toabout 100 parts by weight of the non-solvent components of a coatingcomposition to produce a solvent-inclusive coating composition.

In at least some examples of the coating composition includingtrifunctional silane, silanol fluid, and filler, the trifunctionalsilane may comprise from about 1.5 wt % to about 10 wt % of the coatingcomposition on the basis of non-solvent components, the silanol fluidmay comprise from about 60 wt % to about 95 wt % of the coatingcomposition on the basis of non-solvent components, and the filler(e.g., fumed silica) may comprise from about 3 wt % to about 13 wt % ofthe coating composition on the basis of non-solvent components. In atleast some such examples, the trifunctional silane may include anacetoxy silane and/or a ketoximino silane. In some examples, the coatingcomposition may include one or more catalysts that comprise about 0.02wt % to about 1 wt % of the coating composition on the basis ofnon-solvent components, and/or one or more pigments that comprise about0.02 wt % to about 5 wt. % of the coating composition on the basis ofnon-solvent components.

In at least some such coating compositions, the coating composition mayinclude one or more solvents. For example, the coating composition mayinclude from about 20 parts to about 200 parts by weight of xylene per100 parts by weight of the non-solvent components of the coatingcomposition to produce a solvent-inclusive coating composition, whichmay be applied in some examples via spraying onto a component. Forexample, about 108 parts by weight of xylene may be added to about 100parts by weight of the non-solvent components of a coating compositionto produce a solvent-inclusive coating composition.

In at least some examples, the coating composition may includetrifunctional silane, silanol fluid, and fumed silica. The trifunctionalsilane may comprise from about 2 wt % to about 7 wt % of the coatingcomposition on the basis of non-solvent components, the silanol fluidmay comprise from about 85 wt % to about 92 wt % of the coatingcomposition on the basis of non-solvent components, and the fumed silicamay comprise from about 5 wt % to about 10 wt % of the coatingcomposition on the basis of non-solvent components. In at least somesuch examples, the trifunctional silane may include an acetoxy silaneand/or a ketoximino silane. In at least some such examples, the coatingcomposition may include one or more catalysts that comprise about 0.04wt % to about 0.4 wt % of the coating composition on the basis ofnon-solvent components, and/or one or more pigments that comprise about0.03 wt % to about 1 wt. % of the coating composition on the basis ofnon-solvent components.

In at least some such coating compositions, the coating composition mayinclude one or more solvents. For example, the coating composition mayinclude from about 60 parts to about 130 parts by weight of xylene per100 parts by weight of the non-solvent components of the coatingcomposition to produce a solvent-inclusive coating composition, whichmay be applied in some examples via spraying onto a component.

In at least some examples, the coating composition may includetrifunctional silane, silanol fluid, and fumed silica. The trifunctionalsilane may comprise from about 2 wt % to about 7 wt % of the coatingcomposition on the basis of non-solvent components, the silanol fluidmay comprise from about 85 wt % to about 92 wt % of the coatingcomposition on the basis of non-solvent components, and the fumed silicamay comprise from about 5 wt % to about 10 wt % of the coatingcomposition on the basis of non-solvent components. In at least somesuch examples, the trifunctional silane may include ethyltriacetoxysilane, vinyl triacetoxysilane, methyl tris(methyl-ethyl-ketoximino) silane, and/or vinyl tris(methyl-ethyl-ketoximino) silane.

In at least some examples, the coating composition may includetrifunctional silane, silanol fluid, and fumed silica. In at least somesuch examples, the molar ratio of the trifunctional silane to thesilanol fluid may range from about 5:1 to about 1,000:1, and/or themolar ratio of the fumed silica to the silanol fluid may range fromabout 10:1 to about 1,000:1, with the molecular weight of the fumedsilica equal to the molecular weight of silicon dioxide for the purposeof the ratio calculation. In at least some examples of the coatingcomposition, the molar ratio of the trifunctional silane to the silanolfluid may range from about 20:1 to about 300:1, and/or the molar ratioof the fumed silica to the silanol fluid may range from about 100:1 toabout 300:1, with the molecular weight of the fumed silica equal to themolecular weight of silicon dioxide for the purpose of the ratiocalculation.

A method for preparing a coating composition for application to at leasta portion of an oilfield operational component to reduce damage inducedby flow of a fracking fluid may include providing trifunctional silane,silanol fluid, and filler, and combining the trifunctional silane, thesilanol fluid, and the filler. The method may further include mixing thetrifunctional silane, the silanol fluid, and the filler to obtain thecoating composition. In some examples, the coating composition may beconfigured to form a coating layer on the at least a portion of thecomponent, and the coating layer may be configured to reduce damageinduced by flow of fracking fluid. The mixing may include mixing thetrifunctional silane, the silanol fluid, and the filler to obtain asubstantially homogeneous coating composition. The method may alsoinclude providing a solvent and mixing the solvent with the coatingcomposition. The solvent may include xylene, mineral spirits, and/orother petroleum distillates. In some examples, the solvent may comprisefrom about 10 parts to about 300 parts by weight for each 100 parts byweight of non-solvent components. The method, in some examples, mayinclude providing a catalyst and mixing the catalyst with the coatingcomposition. The catalyst may be a tin catalyst.

A method for providing a flexible coating on a surface of an oilfieldoperational component configured to be exposed to a flow of frackingfluid may include applying a primer composition to an oilfieldoperational component configured to be exposed to a flow of frackingfluid. In some examples, the primer composition may include epoxy. Themethod may also include at least partially curing the primer compositionto obtain a primer layer having a dry film thickness ranging from about20 micrometers to about 100 micrometers. The method may further includeapplying a first coating composition to the primer layer. The firstcoating composition may include at least one of trifunctional silane,silanol, or filler. The method may further include at least partiallycuring the first coating composition to obtain a first coating layerhaving a dry film thickness ranging from about 100 micrometers to about250 micrometers. The method may also include applying a second coatingcomposition to the first coating layer. The second coating compositionmay include trifunctional silane, silanol, and/or filler. The method mayalso include at least partially curing the second coating composition toobtain a second coating layer having a dry film thickness ranging fromabout 100 micrometers to about 250 micrometers. The primer layer, thefirst coating layer, and/or the second coating layer may be configuredto reduce damage to the oilfield operational component from flow of afracking fluid. In some examples of the method, the first coatingcomposition and the second coating composition may be substantially thesame. The method may also include applying at least one an additionalcoating composition to the second coating layer. The at least oneadditional coating composition may include trifunctional silane,silanol, and/or filler. The method may further include at leastpartially curing the at least one additional coating composition toobtain at least one additional coating layer. In some examples, thetotal dry film thickness of the first coating layer, the second coatinglayer, and the at least one additional coating layer may range fromabout 500 micrometers to about 1,000 micrometers. In some examples, atleast two of the first coating composition, the second coatingcomposition, or the at least one additional coating composition aresubstantially the same. In some examples, of the method, applying the atleast one additional coating composition may include applying a thirdcoating composition, and at least partially curing the at least oneadditional coating composition may include at least partially curing thethird coating composition to obtain a third coating layer having a dryfilm thickness ranging from about 100 micrometers to about 250micrometers.

A method for providing an elastic coating on a surface of an oilfieldoperational component configured to be exposed to a flow of frackingfluid may include applying a primer composition to an oilfieldoperational component configured to be exposed to a flow of frackingfluid. The primer composition may include epoxy. The method may alsoinclude at least partially curing the primer composition to obtain aprimer layer having a dry film thickness ranging from about 20micrometers to about 100 micrometers, and applying a first coatingcomposition to the primer layer. The first coating composition mayinclude trifunctional silane, silanol, and/or filler. The method mayalso include at least partially curing the first coating composition toobtain a first coating layer having a dry film thickness ranging fromabout 100 micrometers to about 250 micrometers. The method may furtherinclude applying at least one additional coating composition to thefirst coating layer. The at least one additional coating composition mayinclude trifunctional silane, silanol, and/or filler. The method mayalso include at least partially curing the at least one additionalcoating composition to obtain at least additional coating layer. In someexamples, the total dry film thickness of the first coating layer andthe at least one additional coating layer may range from about 500micrometers to about 1,000 micrometers. In some examples, the primerlayer, the first coating layer, and/or the at least one additionalcoating layer may be configured to reduce damage to the oilfieldoperational component from flow of a fracking fluid.

It has been surprisingly found for at least some examples of the primerlayers and/or the coating layers described herein that they areresistant to erosion by particle impact and/or by cavitation, and thusare effective in protecting fluid handling components, such as oilfieldcomponents, from such erosion by particle impact and/or cavitation. Inat least some examples, the erosion resistance and erosion protectionprovided may be superior to many materials used in fluid handlingcomponents, for example, steel, aluminum, tungsten carbide, and nickel,as demonstrated by the testing results presented herein. At least someexamples of the primer layers and/or the coating layers may be usefulfor providing protection against the effects of impingement and theeffects of impacting particles, such as proppants. For example, asdescribed herein, silanol chains cross-linked by trifunctional silanesmay result in coatings that unexpectedly have useful properties, suchas, for example, erosion resistance, and may significantly prolong theuseful service life of a fluid handling component when used to protectthe fluid handling component from the effects of particle impact,impingement, and/or cavitation.

Without wishing to be bound by theory, it is believed that for at leastsome examples, the primer layers and/or the coating layers describedherein may protect a substrate from erosion and cracking by at least oneof several possible mechanisms. For example, the primer layers and/orthe coating layers may dissipate vibrational energy associated withcavitation on or near the substrate as thermal energy. In at least somesuch instances, the vibrational energy may not reach the substrate andmay not induce the formation of micro-cracks, which may ultimatelyresult in failure in the substrate. Moreover, the primer layers and/orthe coating layers may dissipate kinetic energy associated with theimpact of a particles as thermal energy, and thereby inhibit particlesbefore they reach the substrate, so that the impacting particles cannoterode, chip, and/or deform the substrate. Because, in at least someexamples, the coating layer may absorb vibrational as well as kineticenergy, secondary vibrations that may be induced in the coating layer byimpacting particles may be inhibited, which may prevent transmission ofthe secondary vibrations to the substrate. In addition, in at least someexamples, the coating layer may be flexible, and thus, the coating layermay not impede flexing of the fluid handling component or imposeadditional mechanical stresses on a fluid handling component thatflexes.

For at least some examples, it is believed that the primer layer and/orcoating layer's protection of a substrate, long operating life, andflexibility may be enhanced by the relatively viscoelastic nature of theprimer layer and/or coating layer. This characteristic may helpdissipate kinetic and/or vibrational energy by converting it/them tothermal energy. The elastic nature of the primer layer and/or thecoating layer may allow the primer layer and/or the coating layer to betemporarily deformed by impacting particles and substantially return toits/their original shape within a relatively short time period. Theviscoelastic nature of the primer layer and/or the coating layer mayarise from the molecular structure of the primer layer and/or thecoating layer. For example, a silanol fluid may be a hydroxyl-terminatedpolydialkyl siloxane, for example, polydimethylsiloxane chainsterminated at the ends with hydroxyl groups (PDMS-OH). When notsubjected to stress, a silanol chain may be in a random coilconfiguration. When subjected to stress, however, the chain may extendbut thereafter return to its random coil configuration when the stressis relieved.

It is also believed that the trifunctional silanes may function ascross-linking agents. For example, the trifunctional silanes may reactwith hydroxyl groups on components of the coating composition to formcovalent bonds. When the total number of trifunctional silanes is inexcess of the total number of hydroxyl groups on the components of thecoating composition, all hydroxyl groups may be replaced by functionalgroups from the trifunctional silanes. For example, a trifunctionalsilane may react with hydroxyl groups on the silanol chains, and after asilanol chain has reacted with trifunctional silane, the silanol chainmay be referred to as a functionalized siloxane chain. For example, atriacetoxylated silane may react with a hydroxyl group on a silanolchain to displace the hydroxyl group, release acetic acid, and/or bondto form a siloxane chain with an additional silicon atom and two acetoxygroups at the site were the hydroxyl group was previously located. Whenhydroxyl-terminated silanol chains are used, acetoxy-terminated siloxanechains may be formed. The trifunctional silanes may also react withhydroxyl groups on other components of the coating composition, forexample, hydroxyl groups on a filler and hydroxyl groups on a pigment,to form functionalized components.

It is believed that when the total number of trifunctional silanes is inexcess of the total number of hydroxyl groups on the components of thecoating composition, such that all hydroxyl groups are replaced byfunctional groups from the trifunctional silanes (e.g., acetoxy groups),and no water is present, essentially no further reactions among thefunctionalized siloxane chains (e.g., other functionalized components,such as functionalized filler or functionalized pigment) and thetrifunctional silanes may take place. Thus, the coating composition mayremain liquid as long as it is protected from moisture. However, whenthe coating composition is exposed to water, for example, when thecoating composition is applied to the surface of a fluid-handling partand has contact with moisture in the air, further reaction may occur.For example, in the case of acetoxylated siloxane chains, the water isbelieved to react with the acetoxy groups to form acetic acid andreplace the acetoxy group with a hydroxyl group. The hydroxyl groups onsiloxane chains may thereafter react with remaining acetoxy groups onthe siloxane chains to release acetic acid and form bonds betweensiloxane chains. Similarly, bonds may be formed among other componentsof the composition (e.g., filler and/or pigment), which werefunctionalized, and the siloxane chains. In at least some examples,there is no need for artificially generated heat to be applied in orderto cure the coating layer. Because the trifunctional silanes used toform crosslinks have three functional sites to which a hydroxyl group ona siloxane chain may bond, a network of chains may be formed. In atleast some examples, it may be desirable for the siloxane chains to bondwith filler and/or pigment through reaction of hydroxyl groups withfunctional groups (e.g., acetoxy groups). The filler and/or pigment mayserve as additional crosslink sites, onto which many siloxane chains mayattach. In at least some examples, the siloxane (e.g., the siloxanechains) may be is ultraviolet-resistant, oxidation-resistant,hydrophobic, nontoxic, chemically inert, and/or may exhibit anti-valentproperties. In at least some examples, the it may perform well across arelatively wide range of temperatures and/or may exhibit relatively highvapor permeability.

According at least one hypothesis, the coating layer may have aviscoelastic nature, and when a particle impacts the surface of thecoating layer, the resulting stress temporarily deforms the coatinglayer and stretches the siloxane chains. In the process of deforming,the chains rub against each other, and through friction, a portion ofthe energy of the impact is converted to thermal energy. This conversionto thermal energy through inter-chain friction may account for theviscous nature of the coating layer. After impact, the siloxane chainsmay recoil, and during the recoiling, the chains may rub against eachother, so that the remainder of the energy imparted to the coating layerthrough the particle impact may be converted to thermal energy. Duringthe stretching and recoiling, the crosslinks may act to preserve thetopology of the linked siloxane chains in the coating layer, so that thecoating layer returns to its original shape prior to the particleimpact. It is believed this chain stretching and/or recoiling action mayaccount for the elastic nature of the coating layer. The processes ofchain stretching, recoiling, and interchain friction are also believedto be responsible for the conversion of vibrational energy to thermalenergy (e.g., vibrational energy associated with a cavitation event).According to this hypothesis, the viscoelastic nature of the coatinglayers may promote the ability of the coating layers to resist theeffects of, and protect a substrate from, particle impact, impingement,and/or cavitation.

In at least some examples described herein, a coating composition mayinclude any trifunctional silane and silanol fluid. In at least someexamples, specific components may be selected to control the physicaland chemical properties of the coating layers formed from the coatingcomposition, and a coating composition may be tailored to a specific useor desired result. For example, in certain uses, it may be desirable fora coating layer to be able to stop or protect a substrate from particleshaving high kinetic energy. In at least some such instances, silanolchains having a relatively lower molecular weight may be used, forexample, so that a high cross-link density may be achieved. The largenumber of cross-links per unit volume may serve to prevent too great ofa deformation of the material upon particle impact and allow the energyof a particle impact to be effectively distributed among a large numberof chains to reduce the likelihood that one chain is stretched to thebreaking point. Other uses may render it desirable for coating layersthat transmit relatively less vibration to the surface of the fluidhandling component, or render it desirable that coating layersaccommodate flexing of a fluid handling component. It is believed thatsuch uses may sometimes render it desirable to use silanol chains havingrelatively higher molecular weight, so that a material having arelatively low cross-link density and/or a relatively low modulus may beformed. Thus, for at least some examples, it may be possible to achievea relative balance between hardness and resiliency of a coating layerfor a specific use, for example, by adjusting the molecular weight of atleast some of the silanol chains.

A method for adjusting the hardness of a coating configured to protectat least a portion of component configured to be exposed to a frackingfluid may include preparing a coating composition including an amount oftrifunctional silane, an amount of silanol fluid, and an amount offiller. The method may further include at least one of: (1) increasingthe amount of silanol fluid relative to at least one of the amount oftrifunctional silane or the amount of filler to decrease the hardness ofthe coating; (2) decreasing the amount of silanol fluid relative to atleast one of the amount of trifunctional silane or the amount of fillerto increase the hardness of the coating; (3) increasing the amount offiller relative to at least one of the amount of trifunctional silane orthe amount of silanol fluid to increase the hardness of the coating; or(4) decreasing the amount of filler relative to at least one of theamount of trifunctional silane or the amount of silanol fluid todecrease the hardness of the coating.

A method for adjusting a viscosity of a coating composition forapplication to at least a portion of an oilfield operational componentconfigured to be exposed to a fracking fluid may include preparing acoating composition including an amount of trifunctional silane, anamount of silanol fluid, an amount of filler, and an amount of solvent.The method may also include one of: (1) increasing the amount of solventrelative to at least one of the amount of trifunctional silane, theamount of silanol fluid, or the amount of filler to reduce the viscosityof the coating composition; or (2) decreasing the amount of solventrelative to at least one of the amount of trifunctional silane, theamount of silanol fluid, or the amount of filler to increase theviscosity of the coating composition.

In some examples, the coating composition may be applied directly to thesurface of a substrate, such as a fluid handling component. In someexamples, a primer layer may be applied to the surface of the substrateto improve adhesion of the one or more coating layers to the substrate.Such primer layers may be an epoxy primer. For example, an epoxy primercomposition may be applied to the surface of the substrate and allowedto partially and/or at least substantially cure to form a primer layer.The coating composition may thereafter be applied to the primer layer.In some examples, the primer composition may include an epoxy blendand/or an aliphatic amine. In some examples, the epoxy blend may includeepichlorohydrin and a bisphenol (e.g., Bisphenol-F, for example, EPON®Resin 862, manufactured by Resolution Performance Products LLC, whichmay be a suitable epoxy blend). An example of a suitable aliphatic amineis, for example, EPIKURE™ Curing Agent 3218, manufactured by ResolutionPerformance Products LLC. In some examples, the primer composition mayalso include a silane adhesion promoter, such as, for example, atrimethoxysilane, a triethoxysilane, and/or3-glycidoxypropyltrimethoxysilane. In at least some examples, theadhesion promoter is believed to enhance the chemical bonding of acoating layer including silicone with the primer layer. In someexamples, the primer composition may also include other components, forexample, to control viscosity and/or facilitate application of theprimer composition to the substrate. For example, the primer compositionmay include a leveling agent, a solvent, and/or a pigment. The levelingagent may be a modified urea formaldehyde in butanol (e.g., CYMEL®U-216-8 resin manufactured by Cytec Industries Inc.). The solvent mayinclude a mixture of 2-ethoxyethanol and xylene.

In some examples, the primer composition may include an epoxy blendranging from about 20 wt % to about 95 wt %, include an adhesionpromoter ranging from about 0.5 wt % to about 10 wt %, include analiphatic amine ranging from about 1 wt % to about 20 wt %, and includea leveling agent, solvent, and/or pigment ranging from about 0.01 wt %to about 70 wt %. In some examples, the primer composition may includeabout 26 wt % EPON® Resin 862, about 3.7 wt %3-glycidoxypropyltrimethoxysilane, about 6.8 wt % EPIKURE™ Curing Agent3218, about 0.78 wt % CYMEL® U-216-8 resin, about 42 wt %2-ethoxyethanol, about 13.2 wt % xylene, and about 7.8 wt. % pigment.

In some examples, before applying a primer composition to a surface of afluid handling component, the surface is prepared according to at leastone of several steps. For example, the surface may be cleaned of allforeign matter, such as dust, lint, oils, waxes, corrosion products,oxidation, and/or water. The surface may be prepared by grit-blasting,which may remove foreign matter and provide a mechanical profile, whichmay promote adhesion. Residual dust may be removed via forced air (e.g.,a blowgun). In some examples, after grit-blasting, wiping the surfacewith a cloth or the like may be avoided, for example, so as to avoidcontaminating the surface with lint. In some examples, the primercomposition may be applied within eight hours of preparing the surface,for example, to prevent oxidation of the prepared surface.

In some examples, components of the primer composition may be mixed andallowed to react for a time period ranging from about 20 minutes toabout 30 minutes, before applying the primer composition to the surfaceof the component. The primer composition may be applied to the surfaceof the oilfield operational component (or a fluid handling componentthereof) by spraying the primer composition onto the surface, brushingand/or spreading the primer composition onto the surface, and/or dippingthe oilfield operational component into the primer composition. In someexamples, when the primer composition is applied by spraying,conventional spray equipment may be used. In some examples, the sprayequipment may be of the high-volume, low-pressure (HVLP) type. The cuppressure may be set to range from about 10 pounds per square inch (psi)to about 20 psi, and the air pressure may be set to range from about 30psi to about 40 psi, for example, to enhance atomization.

After the primer composition has been applied to the fluid handlingcomponent, the primer composition may be allowed to cure for a period oftime to form the primer layer. In some examples, the primer compositionmay be allowed to at least substantially cure. In some examples, theprimer composition may be allowed to cure for eight hours or longer. Insome examples, the primer composition may be allowed to cure for twelvehours or longer. In some examples, the primer layer may be tested foradequate cure, for example, by rubbing the primer layer with asolvent-soaked cloth. When adequately cured, the appearance of theprimer layer may generally be unaffected by the solvent and the clothmay not generally pick up any of color of the primer layer. In someexamples, the primer composition may be applied to have a dry filmthickness (e.g., a thickness after evaporation of solvent and/or aftercure) ranging from about 20 micrometers (μm) to about 80 μm. In at leastsome examples, it is believed that when the coating composition isapplied over the primer layer, unreacted functional groups in thecoating composition may react with unreacted functional groups in theprimer layer, thereby resulting in chemical bonding between thefunctional groups.

Example techniques for applying the coating composition to a surface ofa fluid handling component may include, for example, spraying thecoating composition onto the surface, brushing and/or spreading thecoating composition on the surface, and/or dipping the surface into asupply of the coating composition. In some examples, the thickness of acoating layer from which solvent has evaporated and which has at leastpartially cured (i.e., the dry film thickness) may range from about 200μm to about 3,000 μm. In some examples, a coating layer may have a totaldry film thickness ranging from about 500 μm to about 1,000 μm. In someexamples, the coating composition may be applied by spraying using HVLPspraying equipment. In some examples, the cup pressure may be set torange from about 15 psi to about 30 psi, and the air pressure may be setto range from about 35 psi to about 50 psi. In some examples, thecoating composition may be diluted by including xylene and/or mineralspirits. In some examples, airless spray equipment may be used to applythe coating composition. In some such examples, the pressure settings ofthe equipment may range from about 2,000 psi to about 3,300 psi. Forexample, the pressures may range from about 3,000 psi to about 3,300psi. The airless spray technique may reduce the fraction of solventrequired as compared to the fraction of solvent required for sprayingwith HVLP spraying equipment.

In some examples, dry film thicknesses of less than about 200 μm may beobtained through a single transfer of the coating composition to thesurface. The term “transfer” is used to denote the deposition of asingle layer of the coating composition onto the surface of a substrate,such as an oilfield component. For complex and/or vertical surfaces, orto obtain a dry film thickness of greater than about 200 μm, the coatingcomposition may be applied in multiple thin layers. In some examples,the coating composition may be applied to interior surfaces, such asinterior surfaces of a pipe or other component through which fluid mayflow. In some examples, an initial layer of the coating composition maybe applied to achieve a dry film thickness ranging from about 70 μm toabout 100 μm. The initial layer may be allowed to dry substantiallycompletely and at least substantially cure through the completethickness of the coating layer. In some examples, substantially fullcuring may take from about two hours to about three hours. In someexamples, it may be important to not apply an additional layer of thecoating composition prior to substantial curing, because insufficientcuring may induce the previously applied coating layer to separate fromthe surface and/or the primer layer, which may affect adhesion of one ormore of the coating layers to the substrate. In some examples, asubsequent layer may be applied, and the subsequent layer may have a dryfilm thicknesses of up to about 500 μm. In some examples, after thissubsequent coating layer is inspected for separation from the surface oranother coating layer, additional subsequent coating layers may beapplied at about one hour intervals. In some examples, additionalsubsequent coating layers may be applied to obtain a dry filmthicknesses of the coating layers of up to about 500 μm. In someexamples, an initial coating layer having a dry film thickness rangingfrom about 70 μm to about 100 μm may be sprayed onto the surface of thecomponent. This initial coating layer may be allowed to at leastsubstantially cure. A subsequent coating layer may thereafter be sprayedonto the surface of the oilfield operational component and allowed to atleast substantially cure to obtain a total dry film thickness of thecoating layers ranging from about 200 μm to about 600 μm. In someexamples, additional subsequent layers may be sprayed onto the surfaceof the oilfield operational component and allowed to at leastsubstantially cure to obtain a total dry film thickness of the coatinglayers ranging from about 200 μm to about 3,000 μm.

In some examples, a method for maintaining protection of an oilfieldoperational component against erosion by particle impact, impingement,and/or cavitation may include repairing and/or replacing one or morecoating layers. The one or more coating layers may eventually becomeworn after a prolonged period of time, and in some instances, may bedamaged as a result of large and/or sharp objects impacting the coatinglayers or other occurrences. In some examples, a new coating layer maybe applied directly to the worn or damaged coating layer and maygenerally exhibit strong adhesion to the previously applied coatinglayer. In some examples, a damaged coating layer on an oilfieldoperational component may be is repaired by applying a coatingcomposition over the worn or damaged coating layer and allowing theapplied coating composition to substantially dry and at leastsubstantially cure. In some examples, one or more worn or damagedcoating layers may be stripped from the oilfield operational componentbefore applying and curing the coating composition. In some examples,the worn or damaged coating layer may be removed by soaking at least theaffected portion of the oilfield operational component in, for example,mineral spirits for a period of time of two or more hours, which mayresult in the coating layer swelling, and thereafter scraping orotherwise removing the damaged coating layer from the surface of thecomponent. In some examples, the damaged coating layer may be removedvia a focused water jet to cut through the coating layer and lift thecoating layer from the component. In some such examples, the water jetmay be discharged at a pressure of about 2,000 psi or more.

For a coated component having a primer layer under the worn or damagedcoating layer that has been exposed by the worn or damaged coatinglayer, in some examples, the old primer layer may be at least partiallyremoved before a coating composition for a new coating layer is applied.Although the coating composition may adhere strongly to a previouslyapplied coating layer, a new coating layer, in some examples, may notadhere as strongly to an old primer layer. Thus, in some examples, itmay be advantageous to at least a partially remove the old primer layerprior to applying a new coating layer. In some examples, an old primerlayer may be removed by grit blasting, and thereafter in some examples,the coating composition may be directly applied to the surface of thecomponent, or in some examples, primer composition may be applied to theexposed surface of the oilfield operational component to form a newprimer layer before applying the coating composition. In some examples,the surface of the original primer layer (e.g., the primer layer underthe worn or damaged coating layer) may be prepared (e.g., by lightlygrit-blasting the original primer layer to expose a previously-unexposedportion of the primer layer), and thereafter, primer composition may beapplied to the prepared surface of the original primer layer.

For a coated component having one or more coating layers that sufferdamage over a relatively small area, in some examples, in at least someinstances, it may be more economical to repair the one or more coatinglayers in the small area as compared to applying the coating compositionto the entire surface of the component. In some examples, when damage ispresent at only a relatively small area (e.g., the damage is limited toan area of than 6 millimeters across or less), and when the primer layerof the oilfield operational component is not exposed, the damaged areamay be cleaned, for example, to remove foreign matter, a layer ofcoating composition may be applied, and the coating composition may beallowed to at least substantially cure. For examples in which the primerlayer and/or the surface of the oilfield operational component isexposed, primer composition may be applied and allowed to at leastsubstantially cure before applying coating composition. In someexamples, when damage extends over a relatively larger area (e.g., thedamage (e.g., a hole) is present in an area of 6 millimeters or greateracross), the damaged area may be treated or filled with, for example,epoxy mastic. In some such examples, epoxy mastic may be worked into thedamaged area with a putty knife and leveled off such that the surface ofthe epoxy mastic ranges from about 0.5 millimeters to about 1 millimeterbelow a desired final surface. Thereafter, the epoxy mastic may beallowed to at least substantially cure. In some examples, the epoxymastic may be selected to include adhesion-promoting silanes, so thatonce the epoxy mastic has cured, coating composition may be applieddirectly to the surface of the epoxy mastic without prior application ofa primer layer. In some examples, primer composition may be applied tocured epoxy mastic. After the primer composition dries and cures to forma primer layer, the coating composition may be applied. When small areasof damage are repaired, the coating composition may be prepared as apaste, for example, by not including solvent (or not including as muchsolvent). In such examples, the coating composition paste may be appliedby using a caulking gun, putty knife, and/or a brush, and the coatingcomposition paste may be leveled with a putty knife. In some exampleswhere relatively larger areas of damage are repaired, the coatingcomposition may include solvent and may be applied via spraying.

A method for repairing damage to a coating on an oilfield operationalcomponent configured for use in an oilfield operation may includeexposing at least a portion of a first primer layer associated with adamaged portion of the coating, and removing at least a portion of thefirst primer layer to expose a surface of the component. In someexamples, the method may further include applying a primer compositionto the surface of the oilfield operational component and at leastpartially curing the primer composition to obtain a second primer layerbonded to the surface of the component. The method may also includeapplying a coating composition to the second primer layer and at leastpartially curing the coating composition, such that the coatingcomposition at least partially chemically bonds with the second primerlayer. In some examples, exposing the at least a portion of the firstprimer layer may include applying mineral spirits to the coating andscraping at least a portion of the coating to expose the portion of thefirst primer layer. In some examples, removing the at least a portion ofthe first primer layer may include grit-blasting the first primer layer.

A method for replacing at least a portion of a first coating from anoilfield operational component configured for use in an oilfieldoperation may include removing at least a portion of the first coatingfrom the oilfield operational component and exposing at least a portionof the component. The method may also include cleaning the portion ofthe oilfield operational component and applying a primer composition tothe portion of the component. The method may further include at leastpartially curing the primer composition to form a primer layer at leastpartially mechanically bonded to the portion of the component, andapplying a coating composition to the primer layer. The method may alsoinclude at least partially curing the coating composition to form acoating layer at least partially chemically bonded to the primer layer.In some examples, cleaning the portion of the oilfield operationalcomponent may include heating the portion of the oilfield operationalcomponent at a temperature of at least about 650° F. for at least aboutfive hours. Some examples of the method may also include grit-blastingthe portion of the oilfield operational component prior to applying theprimer composition. The method may also include drying the primercomposition for at least twelve hours, at least eighteen hours, or atleast twenty-four hours prior to applying the coating composition to theprimer layer. In some examples, the method may include drying thecoating composition for at least six hours, at least nine hours, or atleast twelve hours and applying a second layer of the coatingcomposition to the coating layer. The method may further include atleast partially curing the second layer of the coating composition toform a second coating layer. In some such examples, the method may alsoinclude drying the second coating layer for a time period of at leastone hour. Thereafter, some examples of the method may also includeapplying a third layer of the coating composition to the second coatinglayer, and at least partially curing the third layer of the coatingcomposition for at least twelve hours, at least twenty-four hours, or atleast thirty-six hours to form a third coating layer.

In some examples, one or more primer layers and/or one or more coatinglayers may be used to protect surfaces of components formed from variousmaterials. For example, the primer layer and/or coating layer may beeffective in protecting surfaces of metal, ceramic, and/or polymer. Forexample, surfaces of steel alloy, stainless steel alloy, aluminum alloy,nickel alloy, titanium alloy, lead alloy, and/or other similar materialsmay be protected. In some examples, surfaces of urethane, epoxy,polycarbonate, acrylic, polyester composite, epoxy composite, and/orother similar materials may be protected. These materials are merelyexamples, and it is contemplated that the surfaces of other materialsknown to those skilled in the art may be protected. In some examples,the primer layer and/or coating layer may exhibit effective resistanceto degradation by elevated temperature.

In some examples, the fractions of components in the primer compositionand/or the coating composition may be adjusted, for example, so that theprimer composition and/or the coating composition may be suitable forany one of a range of application methods, such as, for example,spraying, as well as methods often associated with one-off production,such as brushing and/or spreading. In some examples, no special heattreatment is required to cure the primer composition and/or the coatingcomposition. Once applied to the component, the primer compositionand/or the coating composition may only need to be exposed to the air(e.g., at temperatures close to room temperature).

In some examples, a method for increasing the service life of anoilfield operational component configured to be used in an oilfieldoperation may include at least partially coating the oilfieldoperational component to obtain a first coating layer on the component.The method may also include incorporating the oilfield operationalcomponent into an oilfield operation, and exposing the oilfieldoperational component to fluid flow in the oilfield operation for afirst period of time. The method may further include at least partiallyremoving at least a portion of the first coating layer from thecomponent, and at least partially coating the oilfield operationalcomponent to obtain a second coating layer on the component. In at leastsome examples, the first coating layer and/or the second coating layermay include trifunctional silane, silanol fluid, and filler. In someexamples, the first coating layer and/or the second coating layer may beconfigured to reduce a wear-rate of the oilfield operational componentthat is to be exposed to fluid flow associated with the oilfieldoperation. In some examples, the first period of time may range fromabout 500 hours to about 2,000 hours. In some examples, the method mayalso include exposing the oilfield operational component to fluid flowin the oilfield operation for a second period of time after at leastpartially coating the oilfield operational component to obtain thesecond coating layer on the component. The second period of time mayrange from about 500 hours to about 2,000 hours. A ratio of the firstperiod of time to the second period of time may range from about 1.0 toabout 1.5.

In some examples, the method may further include applying a primercomposition to at least a portion of the oilfield operational componentprior to at least partially coating the component. In some suchexamples, the method may further include at least partially curing theprimer composition prior to at least partially coating the oilfieldoperational component to form a bond between the primer composition andthe component. Some examples may also include at least partially curingthe coating composition to form a chemical bond between the coatingcomposition and the primer composition.

In some examples of the method, it may further include at leastpartially removing at least a portion of the second coating layer fromthe component, and at least partially coating the oilfield operationalcomponent to obtain a third coating layer on the component. In someexamples, the third coating layer may include trifunctional silane,silanol fluid, and filler, and the third coating layer may be configuredto reduce a wear-rate of the oilfield operational component as exposedto fluid flow associated with the oilfield operation. In some examples,the method may further include exposing the oilfield operationalcomponent to fluid flow in the oilfield operation for a third period oftime after at least partially coating the oilfield operational componentto obtain the third coating layer on the component. The third period oftime may range from about 500 hours to about 2,000 hours. A ratio of thefirst period of time and/or the second period of time to the thirdperiod of time may range from about 1.0 to about 1.5.

EXAMPLE 1

Examples of coating compositions for protecting fluid handlingcomponents are presented in Table 1 below. The example coatingcompositions include trifunctional silane, silanol fluid, a filler, apigment, a catalyst, and a cross-linking agent. Dow Corning 3-0134Polymer, manufactured by Dow Corning Corp., was used for the silanolfluid. Dow Corning 3-0134 Polymer contains 400 ppm of hydroxyl groupsand has a viscosity of 50,000 centistokes. Cabot TS-530, which issurface-treated and is manufactured by Cabot Corp., was used for thefumed silica. A transition-metal ferrite spinel powder having a medianparticle size less than 1 μm, F-6331-2 Black Ferro, manufactured byFerro Corporation, was used as the pigment. The catalyst for allexamples is dibutyl tin dilaurate. Four different cross-linking agentswere used for the set of compositions presented in Table 1. Coatingcomposition examples 1-13 include ethyl triacetoxy silane as thecross-linking agent. Coating composition example 14 includes vinyltriacetoxy silane as the cross-linking agent. Coating compositionexample 15 includes methyl tris (methyl-ethyl-ketoximino) silane as thecross-linking agent. Coating composition example 16 includes vinyl tris(methyl-ethyl-ketoximino) silane as the cross-linking agent.

TABLE 1 Fumed Silanol silica Pigment Catalyst Cross-linking Example wt %wt % wt % wt % agent wt % 1 87%  8.3% 0.39% 0.11%  4.6% 2 87%  8.3%0.39% 0.11%  2.8% 3 87%  8.3% 0.39% 0.11%  3.7% 4 87%  8.3% 0.39% 0.11% 5.4% 5 83%  8.1% 0.38% 0.11%  7.2% 6 83%  7.9% 0.38% 0.11%  8.9% 7 91% 4.9% 0.40% 0.11%  4.9% 8 83% 10.4% 0.38% 0.11%  4.5% 9 83% 12.6% 0.38%0.11%  4.5% 10 79% 15.2% 0.35% 0.10%  4.2% 11 78% 18.0% 0.35% 0.10% 4.1% 12 79%  7.5% 0.35% 0.10% 13.5% 13 78%  7.3% 0.35% 0.10% 16.3% 1487%  8.3% 0.39% 0.11%  4.6% 15 87%  8.3% 0.39% 0.11%  5.9% 16 87%  8.3%0.39% 0.11%  6.1%

Table 2 below shows test data including the rate of erosion fromparticle-impact for cured coating layers formed from each of the sixteenexample coating compositions listed in Table 1. The particle-impacterosion-rate data are presented in terms of micrograms of cured coatinglayer worn away per gram of grit blasted against the coating layer. Theerosion-rate testing was performed with a 120-grit particle size aluminablasted at a speed of 600 feet per second at an impact angle of 30degrees with respect to the coating layer surface. Particle-impacterosion-rate data for uncoated 1100 aluminum, uncoated 1008 mild steel,tungsten carbide, and nickel are also shown for comparison. Theparticle-impact erosion-rate data corresponds to the mass of metal wornaway for each of the examples. The tungsten carbide is a high velocityoxy fuel (HVOF) sprayed coating including 17 wt. % cobalt. Table 2 alsoshows data for the rate of loss of each of the coating layers associatedwith cavitation. The cavitation loss-rate data are presented in terms ofmilligrams of cured coating layer worn away per hour of exposure tocavitation. The cavitation testing was performed with the coating layersimmersed in water and an ultrasonic horn vibrating at 20 kHz in thewater spaced 0.5 millimeters from the respective coating layer surface.Cavitation loss-rate data for uncoated 1100 aluminum and uncoated 1008mild steel are also shown for comparison. The cavitation loss-rate datacorresponds to the mass of metal worn away for these examples.

TABLE 2 Particle-impact Cavitation Example/ erosion-rate loss-rateMaterial μg_(surface)/g_(grit) mg_(surface)/hour 1 4.2 — 2 4.3 2.3 3 4.3— 4 4.6 2.1 5 4.7 — 6 5.2 2.5 7 3.6 2.7 8 5.4 2.4 9 6.4 — 10 7.4 3.6 115.6 2.4 12 5.1 1.7 13 5 2.4 14 4.6 3.5 15 5.5 3.5 16 5.8 3.5 Aluminum1100 58.6 39 Steel 1008 99.3 10 Tungsten carbide 69.9 — Nickel 129.2 —

The greatest particle-impact erosion-rate of the coating layers wasobserved for the cured coating layer formed from coating compositionexample 10, which was 7.4 mμ_(surface)/g_(grit). The particle-impacterosion-rate for example 10 is only about 13% of the particle-impacterosion-rate of uncoated 1100 aluminum and is only about 7% of theparticle-impact erosion-rate of uncoated 1008 mild steel. Thus, theexample coating compositions result in coating layers that exhibit muchbetter erosion resistance than the two uncoated metals tested. Thegreatest cavitation loss-rate of a coating layer was observed for thecured coating layer formed from coating composition example 10, whichwas 3.6 mg_(surface)/hour. This cavitation loss-rate is only about 9% ofthe cavitation loss-rate of uncoated 1100 aluminum and is only about 36%of the cavitation loss-rate of uncoated 1008 mild steel. Thus, theexample coating compositions result in coating layers that exhibit muchbetter cavitation resistance than the two uncoated metals tested.

EXAMPLE 2

Table 3 below shows six example coating compositions including silanol,filler, a pigment, a catalyst, and a cross-linking agent. The filler isfumed silica, the pigment is a transition-metal ferrite spinel powderhaving a median particle size less than 1 μm, F-6331-2 Black Ferro,manufactured by Ferro Corporation, the catalyst is dibutyl tindilaurate, and the cross-linking agent is ethyl triacetoxy silane.

TABLE 3 Silanol Filler Pigment Catalyst Cross-linking Example wt % wt %wt % wt % agent w t% A 40% 0.01% 0.01% 0.01% 0.01% B 99%   25%   10%  5%   20% C 60%   3% 0.02% 0.02%  1.5% D 95%   13%   5%   1%   10% E85%   5% 0.03% 0.04%   2% F 92%   10%   1%   0.4%   7%

When the example coating compositions C, D, E, or F are applied to andcured on a fluid handling component, the particle-impact erosion-rate ofthe resultant coating layer would be expected to be similar to theerosion rates for coating layers exhibited by the example coatingcompositions 1-16 shown in Table 2 under similar conditions of blastingwith 120-grit size alumina at a speed of 600 feet per second and animpact angle of 30 degrees. The cavitation loss rate of example coatinglayers formed from the example coating compositions C, D, E, or F wouldbe expected to be similar to the cavitation loss rates for coatinglayers formed from example compositions 1-16 shown in Table 2 undersimilar conditions of sonication with the coating layers immersed inwater and an ultrasonic horn vibrating at 20 kHz in the water spaced 0.5millimeters from the respective coating layer surface. Example coatingcompositions A and B have weight percentages of components differentthan the example coating compositions 1-16 shown in Table 1. Theparticle-impact erosion-rate and cavitation loss rate for coating layersformed from the example coating compositions A and B may differ from theresults for the coating layers formed from the example coatingcompositions 1-16. However, the coating compositions A and B, when curedon a fluid handling component, would be expected to result in usefulrespective coating layers that would provide effective protection of thefluid handling component against erosion by particle impact,impingement, and/or cavitation.

Use of a pigment other than Black Ferro F-6331-2 in a coatingcomposition would be expected to, upon curing, result in a coating layerexhibiting properties similar to that of a coating layer formed from acoating composition in which Black Ferro F-6331-2 is used (e.g., similarerosion-resistance and protection of a fluid handling component fromerosion by particle impact, impingement, and/or cavitation). Use of atin catalyst and/or one of many other catalysts not based on tin, otherthan dibutyl tin dilaurate, and use of a cross-linking agent other thanethyl triacetoxy silane, such as, for example, vinyl triacetoxy silane,methyl tris (methyl-ethyl-ketoximino) silane, or vinyl tris(methyl-ethyl-ketoximino) silane, would be expected to, upon curing,result in a respective coating layer exhibiting properties similar tothat of a coating layer formed from a composition in which dibutyl tindilaurate and ethyl triacetoxy silane are used (e.g., similarerosion-resistance and protection of a fluid handling component fromerosion by particle impact, impingement, and/or cavitation).

Example Method

An example method at least according to some examples described hereinfor forming one more primer layers and one or more coating layers willnow be described. Unless noted herein, the order of the described stepsis not necessary for performing methods consistent with the methodsdescribed herein, some steps may be optional, and additional steps arenot inconsistent with the methods described herein.

In some examples of the method, prior to applying a primer compositionor a coating composition to the oilfield operational component to betreated, the oilfield operational component may be visually inspectedfor damage or surface irregularities prior to treatment. Any surfaceirregularities in the component, such as hard surface layers, sharp edgefillets, corners, and welds may be removed by an appropriate methodprior to surface preparation of the component. In some examples, theoilfield operational component may be solvent-cleaned (e.g., MEK) and/orvapor-degreased (e.g., according to ASTM D4126), for example, forcomponents that have been previously in service. In some examples, theoilfield operational component may be cleaned, degreased, and/orthermally degreased by baking the oilfield operational component in anoven to achieve about a 700° F. component temperature for about eighthours to substantially or fully remove potential contaminants. In someexamples, machined surfaces and/or any other portion of the oilfieldoperational component that may be damaged by grit blasting may bemasked-off prior to grit-blasting to protect those portions of theoilfield operational component from the grit-blasting.

In some examples of the method, the ambient conditions in the processingarea may be checked, and, in some examples, a blotter test may beperformed (e.g., according to ASTM 4285-83). If ambient conditions aresuitable, the oilfield operational component may be grit-blasted orwhite-metal-blasted with an aluminum oxide abrasive media sized with 100mesh according to NACE NO. 1/SSPC-SP5 (e.g., white metal blast). In someexamples, the oilfield operational component surface temperature may bemaintained at a temperature of at least 5° F. above the dew point.

In some examples of the method, the oilfield operational component maybe grit-blasted to develop an anchor pattern of about 20 μm to about 30μm. In some examples, the Testex Press-O-Film Replica Tape method may beused for verifying the anchor profile. The tape profile may be measuredusing a spring micrometer (e.g., according to ASTM D4417).

In some examples of the method, following grit-blasting, the method mayfurther include applying a primer composition consistent with at leastsome examples of primer compositions described herein. In some examples,the primer composition may be applied relatively soon after cleaning,for example, within about four hours following grit-blasting. Anyhumidity may cause flash-rusting of the oilfield operational componentif formed from steel, and if such flash rusting is observed, the methodmay include performing the grit-blasting again. In some examples of themethod, applying the primer composition to the oilfield operationalcomponent may occur only if the ambient temperature is greater thanabout 40° F., and the relative humidity is less than about 85%, or whenthe oilfield operational component temperature is greater than about 5°F. above the dew point. The primer composition may be applied via asprayer that atomizes the primer composition.

In some examples of the method, a 2.5-gallon pressure paint pot may beused with a dual regulator. The pressure pot may be set at an airpressure ranging from about 40 psi to about 60 psi, and a fluid pressureranging from about 15 psi to about 20 psi. In some examples, prior toapplication of the primer composition, the surface of the oilfieldoperational component to receive the primer composition may be blastedwith compressed air to reduce the chance of any surface contamination.

Some examples of the method may include applying the primer compositionto achieve a dry film thickness ranging from about 20 μm to about 50 μm.In some examples, the method may include drying or curing the primercomposition for forty-eight hours at about 70° F. (e.g., in an ambientstate), or in some examples, for seventy-two hours if the temperature isbelow 70° F.

Some examples of the method may also include testing the primer layer todetermine whether it has sufficiently cured, for example, by rubbing theprimer layer surface with a cotton swab dipped in xylene. If the tip ofthe cotton swab blackens, it may be an indication that additional curingof the primer composition should be performed.

In some examples of the method, prior to applying the coatingcomposition to the dried or cured primer layer, the method may includewiping the primer layer surface clean, for example, using a lint-freecloth to avoid contamination of the primer layer surface, as suchcontamination may result in insufficient adherence of the coatingcomposition to the primer layer.

In some examples of the method, an airless spraying pump may be used toapply the coating composition. The coating composition may be appliedvia a sprayer that atomizes the coating composition. In some examples, aspin-coating tool may be used with the pump, so that the coatingcomposition may be applied to interior surfaces of a fluid handlingcomponent. In some examples, the coating composition may be applied toachieve a coating thickness of about 50 μm or thicker by successiveapplication about every ten minutes. In some examples, the air pressureof the airless pump may be set to a pressure ranging from about 15 psito about 20 psi.

In some examples, the coating composition may be applied to the oilfieldoperational component to achieve a dry film thickness ranging from about150 μm to about 200 μm. Once applied, the coating composition may becured for a time period ranging from about ten hours to abouttwenty-four hours at a temperature of about 70° F. (e.g., in an ambientstate). Thereafter, an additional layer of the coating composition maybe applied to the at least partially cured layer of coating compositionto achieve an additional coating layer dry film thickness ranging fromabout 150 μm to about 200 μm. In some examples, this additional coatingcomposition layer may be cured for a time period ranging from about onehour to about three hours at a temperature of about 70° F.

Thereafter, in some examples, a second additional layer of the coatingcomposition may be applied to the at least partially cured additionallayer of coating composition to achieve a second additional coatinglayer dry film thickness ranging from about 150 μm to about 200 μm. Insome examples, this second additional coating composition layer may becured for a time period ranging from about thirty-six hours to abouteighty-four hours (e.g., about seventy-two hours) at a temperature ofabout 70° F., for example, in a well-ventilated area having a relativehumidity ranging from about 30% to about 70%. In some examples, themethod may include curing the final coating composition layer for aminimum of seven days prior to use of the component. Additional layersof the coating composition may be applied and/or cured, for example, inan at least similar manner as described above. Following applicationand/or curing of a final layer of the coating composition, the at leastpartially coated oilfield operational component may be inspected priorto being placed in service.

FIG. 8 is a schematic illustration of an example coating assembly 116configured to apply a coating composition to oilfield operationalcomponents according to the disclosure. As shown in FIG. 8, in someembodiments, the coating assembly 116 may include an airless pump 118configured to pump a supply of the coating composition (or the primercomposition) via a fluid line 119 from a reservoir 120 to a spray gun122 via a fluid line 124 (e.g., an airless fluid hose). As shown, someembodiments of the spray gun 122 may include a wand 126, which in someexamples may include a back pressure orifice 128. In some embodiments,the spray gun 122 may include an activation trigger 130 configured tocause the coating composition to be conveyed via a second fluid line 132to a coating tool 134. In some embodiments, for example, as shown, thecoating tool 134 may include a spray head 136 configured to rotate anddischarge the coating composition from a plurality of spray orifices 138as the spray head 136 rotates. For example, the spray head 136 mayinclude an air motor configured to rotate the spray head 136 via airpressure supplied via an air line 140 from an air source 142 (e.g., apressurized air tank and/or an air compressor). For example, the sprayhead 136 may be inserted into the interior 144 of a component 146 havingan interior surface 148 to which the coating composition is to beapplied. The air may be supplied to the spray head 136 to cause the airmotor to rotate the spray head 136, and the airless pump 118 may supplythe coating composition to the coating tool 134 and the spray head 136under pressure, thereby atomizing the coating composition as it isforced through the spray orifices 138. In some examples, the wand 126(i.e., rather than the spray head 136) may be inserted into the interior144 of the component 146 to which the coating composition is to beapplied, and the activation trigger 130 of the spray gun 122 may beengaged to manually apply the coating composition to the interiorsurface 148 of the component 146 as will be understood by those skilledin the art.

In some embodiments, the airless pump 118 may be configured to have anoutput ratio ranging from about 10:1 to about 100:1, such as from about20:1 to about 90:1, from about 30:1 to about 80:1, from about 40:1 toabout 70:1, or from about 50:1 to about 65:1 (e.g., about 60:1). Forexample, if air from the air source 142 is supplied at about 100 poundsper square inch (psi) and the airless pump 118 has an output ratio ofabout 60:1, the coating composition may be forced through the sprayorifices 138 at about 6,000 psi, which may result in atomizing thecoating composition into fine particles as the coating compositionpasses through the spray orifices 138. In some embodiments, atomizingthe coating composition in such a manner when applying it to a surfacemay result in a relatively smoother surface finish, which in someembodiments, may result in a more damage-resistant surface as will beunderstood by those skilled in the art.

Testing

Erosion tests were conducted on samples of steel coated with a coatingcompositions consistent with the example coating compositions describedherein. The objective of the testing was to measure and document theresistance to erosion from sand-laden slurry representative of afracking fluid, with the coating layer formed by the coating compositionapplied to the interior surface (e.g., through which fracking fluidwould flow) of common fracking system components, including a goat head,a fluid end, and a frac iron component. Unless otherwise noted below,the coating layer on the test samples was 0.014 inches thick and formedfrom the same coating composition, which is consistent with at leastsome of the coating compositions described herein. Several basematerials commonly used to form a goat head, a fluid end, and a fraciron component were used to form the test samples as follows: alloysteel AISI 4130 API-spec steel, commonly used to form a goat head;stainless steel 17-4 PH, commonly used to form a fluid end; and alloysteel AISI 4715, commonly used to form frac iron components. The testingincluded direct impingement flow with a constant differential pressureof silicon dioxide (SiO₂) sand against test samples coated with a curedcoating composition consistent with at least some examples of thecoating compositions described herein and bare test samples (i.e.,uncoated test samples). The tests were typically continued for fourhours beyond coating layer breakthrough, at a constant slurry flow rate,with the test paused every four hours to document the condition of thetest sample after each flow interval. Typically, the total test time ofthe bare test samples matched the total test time of the correspondingtest sample having the tested coating layer. For each test sampletested, tests for four impingement angles were performed for comparison:0°, 30°, 45°, and 60°. A constant jet nozzle exit velocity was usedacross all tests.

FIGS. 9A, 9B, 9C, and 9D are a schematic representations of a testingarrangement 150 including a test sample 152 exposed to a test fluid flow154 discharged from a nozzle exit 156 with the test sample 152 atincluded impingement angles β relative to horizontal (as depicted),including 0° (FIG. 9A), 30° (FIG. 9B), 45° (FIG. 9C), and 60° (FIG. 9D).The size of each test sample 152 was three inches in diameter andone-half inch thick. Each test sample 152 was machined with twoone-quarter-inch threaded holes on the back side to enable installationof the test sample 152 into a holder (not shown). For the test samples152 having a coating layer, the surface of the test sample 152 wasshot-blasted prior to applying the coating composition. Aftershot-blasting, a primer composition consistent with at least someexample primer compositions described herein was applied the testsamples 152, such that a primer layer having a dry film thickness ofabout 25 μm was formed on the test sample. This was followed byapplication of a coating composition consistent with at least some ofthe coating compositions described herein to form a coating layer havinga dry film thickness of about 30 μm to about 36 μm. All metallicsurfaces were prepared the same way, so that the test sample substratematerial properties would be consistent.

The AISI 4715 material used for manufacturing test samples wascarburized and exhibited a surface hardness of 62 HRC. This material wasalso case-hardened to 44 HRC to a depth of about 1,780 μm. The corehardness of the test samples was approximately 35 HRC. The AISI 4130material used for manufacturing the test samples was standard API 75-ksimaterial. The hardness requirement per API is about 207 to about 35 HBW.The MTRs for this material lists a hardness of about 212 to about 227HBW.

Regarding the fluid flow for the testing, a jet velocity of about 100feet per second was used for all test samples and impingement angles.This jet velocity was selected to increase the erosion rate and reduceoverall test time, so that notable changes would be expected within afour-hour test interval. A single, substantially constant jet velocitywas used to reduce the number of test variables and to minimize thenumber of changes required to the test fixture and related equipment.Regarding the composition of the fluid flow, the test slurry wascomposed of tap water with erodent particles added at a concentration of20,000 parts per million by weight. At the flow rates selected fortesting, this concentration represents a consumption of approximately200 pounds of sand erodent for every four hours of testing. Aconcentration of 20,000 parts per million by weight is a petroleumindustry standard value and is specified in several American PetroleumInstitute (API) standards. It is believed that concentrations exceeding20,000 parts per million by weight may result in particle-to-particleinteractions that cause the specific erosion (i.e., the total mass ofmaterial eroded normalized by dividing it by the total mass of erodent)to shift from a linear relationship to a nonlinear relationship.

The erodent material selected for small sand tests was “270 mesh” silicaflour, and the erodent material selected for large sand tests was “100mesh” silica flour. The relatively smaller 270 mesh sand had particlesize distribution of a D₁₀ of about 5 μm, a D₅₀ of about 51 μm, and aD₉₀ of about 130 μm. The relatively larger 100 mesh sand had a particlesize distribution of a D₁₀ of about 118 μm, a D₅₀ of about 194 μm, and aD₉₀ of about 332 μm. The silica material was produced by processingrounded Midwest sands to a finer particle size to achieve the desiredparticle size distributions. This results in a petroleumindustry-accepted representation of solids in fracking fluid, and isrecommended for erosion flow testing in API standards including API19ICD (Inflow Control Devices) and API 19ICV (Interval Control Valves).The Mohs hardness for silica ranges from 6 to 7.

The sand particles mixed in the slurry were passed through the testset-up once and thereafter discarded (i.e., they were not recycled backthrough the testing arrangement). This procedure was used becauseparticles of silica have sharp corners or edges after being ground, andthe sharp corners or edges may be smoothed/rounded off after multiplepasses through the testing arrangement via interactions with otherparticles and the test sample. A single-pass design more consistentlyimpacts the test samples with the most abrasive erodent. Thissingle-pass approach is also believed to be the most representative offield conditions during a fracking operation.

The general test procedure used follows:

-   -   1. Weigh the test sample prior to testing on a gram scale with a        resolution of 0.01 gram;    -   2. Install the test sample into the test sample holder;    -   3. Obtain a slurry sample and measure particle concentration to        verify target particle loading;    -   4. Begin flow testing while maintaining flow parameters constant        in their respective defined ranges. After each two hours of        erosion flow, obtain a new slurry sample to confirm that        particle concentration remains in the defined range;    -   5. After each four-hour testing interval, which corresponds to a        total sand flow of approximately 200 pounds, pause the test and        remove the test sample from the holder. Clean the test sample        and weigh it to document the weight of material lost, and        photograph the wear area to document its current condition;    -   6. Measure the maximum wear depth in the test sample using a        depth gauge; and    -   7. Repeat steps 1 through 6 for another four-hour interval, and        continue repeating flow intervals for a cumulative flow period        of at least sixteen hours. After sixteen hours of testing is        complete, decide whether the test should be further continued,        for example, if the coating layer has not yet been breached or        is only marginally damaged. Continue testing until a trend in        the results is apparent and documented.

Test Results

For the AISI 4130 alloy steel often used in goat heads, twelve testswere performed with the twelve test samples, including four test samples(i.e., Samples B, F, J, and L) coated with a coating compositionconsistent with at least some examples described herein to form acoating layer 0.014 inches thick, and four uncoated (bare) test samples(i.e., Samples A, E, I, and K). In addition, two test samples werecoated with a coating composition consistent with at least some examplesdescribed herein to form a (“Thick-coated”) layer of 0.028 inches thickinstead of 0.014 inches thick (i.e., Samples C and G), and two testsamples were coated with a modified coating composition(“Chem.-resist.-coated”) consistent with at least some examplesdescribed herein to form a coating layer thickness of 0.014 inches(i.e., Samples D and H).

The modified coating composition was modified relative to at least someexample coating compositions described previously herein to bechemically-resistant (or at least relatively more chemically-resistantas compared to the non-modified coating compositions) to fluidsprevalent in oilfield settings, such as fracturing fluids and/orpetroleum. For example, some embodiments of the coating compositiondescribed previously herein may include silanol fluid in an amountranging from about 40 wt % to about 90 wt %, fumed silica in an amountranging from about 0.01 wt % to about 25 wt %, and/or a catalyst (e.g.,dibutyl tin dilaurate) in an amount ranging from about 0.01 wt % toabout 10 wt %. In some embodiments of the modified coating composition,the amount (or amounts) of one or more (or a combination) of the silanolfluid, the fumed silica, or the catalyst, relative to the coatingcompositions previously described herein, may be reduced by an amountranging from about 1 wt % to about 10 wt %, from about 2 wt % to about 9wt %, from about 3 wt % to about 8 wt %, from about 4 wt % to about 7 wt%, or from about 4 wt % to about 6 wt % (e.g., about 5 wt %, forexample, about 5.2 wt %). In some embodiments, the wt % given may be forcured coatings, for example, after solvents and/or volatiles have beenlost and/or eliminated.

In some embodiments, the modified coating composition may includesilanol fluid in an amount ranging from about 75.0 wt % to about 85.0 wt%, from about 76.0 wt % to about 84.0 wt %, from about 77.0 wt % toabout 83.0 wt %, from about 78.0 wt % to about 82.0 wt %, from about79.0 wt % to about 82.0 wt %, from about 80.0 wt % to about 82.0 wt %,or from about 80.0 wt % to about 81.0 wt % (e.g., about 80.7 wt %). Insome embodiments, the modified coating composition may include an amountof fumed silica ranging from about 13.0 wt % to about 17.0 wt %, fromabout 14.0 wt % to about 16.0 wt %, from about 14.5 wt % to about 15.5wt %, or from about 15.0 wt % to about 15.5 wt % (e.g., about 15.1 wt%). In some embodiments, the modified coating composition may include anamount of catalyst (e.g., dibutyl tin dilaurate) ranging from about 0.15wt % to about 0.21 wt %, from about 0.16 wt % to about 0.20 wt %, orfrom about 0.17 wt % to about 0.19 wt % (e.g., about 0.18 wt %). In someembodiments, the cured and dried coating composition may include, forexample, substantially all functional types of silanol grouped togetherand including silane chains and T-resins.

Some embodiments of the coating composition previously described hereinmay include one or more cross-linking agents (e.g., trifunctionalsilane, such as ethyl triacetoxysilane) in an amount ranging from about1 wt % to about 20 wt % (e.g., from about 2 wt % to about 7 wt %). Insome embodiments of the modified coating composition, the amount ofcross-linking agent(s) (e.g., ethyl triacetoxysilane), relative to thecoating compositions previously described herein, may be increased by anamount ranging from about 1 wt % to about 10 wt %, from about 2 wt % toabout 9 wt %, from about 3 wt % to about 8 wt %, from about 4 wt % toabout 7 wt %, or from about 4 wt % to about 6 wt % (e.g., about 5 wt %,for example, about 5.2 wt %). In some embodiments, the cross-linkingagent(s) (e.g., ethyl triacetoxy silane) may react with other silanol,fumed silica, and/or moisture from the air. In some such embodiments,the coating composition may cure to form polymers, copolymers, and blockpolymers that may be collectively referred to as “ethyl T-resins,” eachunit forming three links and/or bonds where each link and/or bond is toanother unit of ethyl T-resin, a silanol, a surface of fumed silica,and/or the surface of other constituents, such as pigments.

In some such embodiments, the coating composition may include ethylT-resin in an amount ranging from about 2.0 wt % to about 3.5 wt %, fromabout 2.2 wt % to about 3.3 wt %, from about 2.4 wt % to about 3.1 wt %,from about 2.5 wt % to about 3.0 wt %, or from about 2.6 wt % to about2.9 wt % (e.g., about 2.8 wt %). In some embodiments, the modifiedcoating composition (e.g., the chemically-resistant coating composition)may include ethyl T-resin in an amount ranging from about 2.0 wt % toabout 3.5 wt %, from about 2.2 wt % to about 3.3 wt %, from about 2.4 wt% to about 3.1 wt %, from about 2.5 wt % to about 3.0 wt %, or fromabout 2.6 wt % to about 2.9 wt % (e.g., about 2.7 wt %). It is believedby Applicant that the level of ethyl T-resin in the cured coating mayenhance the performance and/or the durability of the coatings. In someembodiments, the amount of ethyl T-resin in the modified coatingcomposition may be less than about 5 wt % and/or more than about 1.5 wt% (e.g., an amount ranging from about 1.9 wt % to about 3.3 wt % (e.g.,from about 2.6 wt % to about 2.9 wt %)).

Some embodiments of the coating composition previously described hereinmay include one or more pigments (e.g., one or more black pigments, suchas transition-metal ferrite spinel powder) in an amount ranging fromabout 0.01 wt % to about 15 wt %. In some embodiments of the modifiedcoating composition, the amount of pigments (e.g., black pigment),relative to the coating compositions previously described herein, may bereplaced by one or more blue pigments in an amount ranging from aboutone to about fifteen times the amount of black pigment, from about threetimes to about fifteen times the amount of black pigment, from aboutfive times to about fifteen times the amount of black pigment, fromabout eight times to about fourteen times the amount of black pigment,or from about ten times to about twelve times the amount of blackpigment. In some embodiments, blue pigment may be included in an amountranging from about 1.0 wt % to about 5.0 wt %, from about 1.5 wt % toabout 4.5 wt %, from about 2.0 wt % to about 4.5 wt %, from about 2.5 wt% to about 4.0 wt %, from about 3.0 wt % to about 4.0 wt %, from about3.5 wt % to about 4.0 wt %, or from about 3.5 wt % to about 3.8 wt %(e.g., about 3.6 wt %). In some embodiments, the blue pigment mayinclude Cobalt Aluminate Blue Spinel, Cas #1345-16-0. Other bluepigments and/or pigments of other colors are contemplated.

Some embodiments of the coating composition previously described hereinmay not include titanium dioxide or may include only a relatively small(trace) amount of titanium dioxide. In some embodiments of the modifiedcoating composition, titanium dioxide may be included in an amountranging from about 0.01 wt % to about 15 wt %, from about 1 wt % toabout 14 wt %, from about 3 wt % to about 12 wt %, from about 5 wt % toabout 10 wt %, from about 6 wt % to about 9 wt %, or from about 7 wt %to about 8 wt %. For example, titanium dioxide may be included in anamount ranging from about 0.50 wt % to about 0.90 wt %, from about 0.60wt % to about 0.85 wt %, from about 0.65 wt % to about 0.80 wt %, fromabout 0.70 wt % to about 0.80 wt %, or from about 0.70 wt % to about0.75 wt % (e.g., about 0.72 wt %).

Relative to some embodiments of the non-modified coating compositionpreviously described herein, it is believed by Applicant that for someembodiments of the modified coating composition, adding titanium dioxidemay increase the durability of the cured coating layer(s). It is alsobelieved by Applicant that for some embodiments of the modified coatingcomposition, adding additional cross-linking agent(s) (e.g.,trifunctional silane) to the coating composition, and/or removing someof the polymer (e.g., silanol fluid) from the coating composition, maypromote a relatively tighter bond between the cross-linking agent(s) andpolymer and/or promote additional crosslinking between the blue pigmentand the titanium dioxide. For some embodiments, it is also believed byApplicant that relatively tighter bonds may reduce the permeability ofthe coating layer, which may reduce the susceptibility of the coatinglayer to attack from solvents and/or other chemicals to which theoilfield operational component may be exposed.

Samples A through D were tested at an impingement angle of 0°. Samples Ethrough H were tested at an impingement angle of 30°. Samples I and Jwere tested at an impingement angle of 45°, and Samples K and L weretested at an impingement angle of 60°. The results of the tests areprovided in Table 4 below, showing the cumulative mass loss (grams (g))and cumulative wear depth (inches (in)) as a function of the time duringwhich the Samples were subjected to the testing. FIG. 10 is a graph ofcumulative wear depth (inches (in)) versus testing time (hours (hr))during which the Samples were subjected to the testing for the testresults shown in Table 4.

TABLE 4 Coating/ Jet Angle Duration Mass loss Wear Sample Bare (degrees)(hours) (g) depth (in) A Bare 0 4 1.04 0.038 8 1.81 0.063 12 2.62 0.08716 3.28 0.105 B Coated 0 4 0.00 0.000 (0.014 in) 8 0.00 0.000 12 0.390.016 16 0.96 0.040 C Thick- 0 4 0.00 0.007 coated 8 0.00 0.010 (0.028in) 12 0.00 0.011 16 0.00 0.013 20 0.00 0.016 24 0.01 0.017 28 0.600.042 32 0.86 0.067 D Chem.- 0 4 0.00 0.003 resist- 8 0.00 0.005 coated12 0.00 0.006 (0.014 in) 16 0.01 0.008 20 0.42 0.034 24 0.72 0.062 EBare 30 4 1.03 0.054 8 1.71 0.081 12 2.53 0.106 16 3.10 0.122 F Coated30 4 0.00 0.000 (0.014 in) 8 0.02 0.000 12 0.66 0.061 16 1.24 0.092 GThick- 30 4 0.00 0.003 coated 8 0.00 0.006 (0.028 in) 12 0.00 0.009 160.00 0.012 20 0.00 0.014 24 0.00 0.015 28 0.00 0.017 32 0.39 0.053 361.18 0.082 H Chem.- 30 4 0.00 0.002 resist- 8 0.00 0.006 coated 12 0.010.009 (0.014 in) 16 0.01 0.010 20 0.20 0.051 24 0.56 0.093 I Bare 45 40.86 0.040 8 1.49 0.065 12 2.30 0.090 16 2.90 0.112 J Coated 45 4 0.010.000 (0.014 in) 8 0.01 0.000 12 0.28 0.020 16 0.71 0.039 K Bare 60 40.74 0.035 8 1.23 0.056 12 1.88 0.079 16 2.32 0.092 20 2.82 0.105 243.17 0.114 L Coated 60 4 0.00 0.000 (0.014 in) 8 0.00 0.000 12 0.010.000 16 0.01 0.000 20 0.16 0.023 24 0.39 0.040

As shown in FIG. 10, for the AISI 4130 alloy steel consistent withmaterial typically used in goat heads, the cumulative wear depth for theeach of the bare testing samples, regardless of impingement angle, wassignificantly greater as compared to the cumulative wear depth for thecoated test samples, regardless of the coating thickness or whether thecoating was the modified coating (i.e., the chemical-resistant coating).In addition, as shown in Table 4, the cumulative mass loss for the eachof the bare testing samples, regardless of impingement angle, wassignificantly greater as compared to the cumulative mass loss for thecoated test samples, regardless of the coating thickness or whether thecoating was the modified coating. In addition, the coated test samplesdo not show any significant wear depth or mass loss prior to two hoursof testing (i.e., about 400 pounds of sand passed), and for an angle of60°, no significant mass loss occurs until four hours of testing (i.e.,about 800 pounds of sand have passed). (The test samples were subjectedto approximately 200 pounds of sand erodent for every four hours oftesting.) As would generally be expected, the amount of mass lossdecreases with the angle of impingement, for example, such that the massloss at 60° is significantly less than for 0° at a given testing time orpassage of sand. The results of the testing suggest the tested primerlayer and coating layer may significantly increase the service life of afluid handling component for an oilfield operation, such as a goat headassociated with a fracturing system.

In addition, as shown in FIG. 10, the bare samples (Samples A, E, I, andK) all reach a wear depth of 0.014 inches in two hours or less oftesting. In contrast, coated Sample F, which exhibited the quickest wearrate of the coated samples, only reached a wear depth of 0.014 inchesafter eight hours of testing, a four-fold decrease in wear rate. Inaddition, Samples C and G, which included the thick coating (0.028inches) did not reach 0.014 inches of wear depth until sixteen hours andtwenty hours of testing, respectively. Comparing coated Samples B and F,which included the 0.014-inch thick coating layer, to the coated SamplesC and G, which included the 0.028-inch thick coating layer, it tooktwice as long for Samples C and G to reach a 0.140-inch wear depth asSamples B and F. Regarding Samples D and H, which included thechemical-resistant coating layer (0.014 inches thick), Samples D and Hdid not reach a wear depth of 0.014 inches until after sixteen hours oftesting. Sample B, tested at an impingement angle of 0 degrees andhaving a coating thickness of 0.014 inches, exhibited 0.014 inches ofwear depth in a little more than half the time (ten hours) of Sample D(seventeen hours), tested at an impingement angle of 0 degrees andhaving a chemical-resistant coating of 0.014 inches thick. Sample F,tested at an impingement angle of 30 degrees and having a coatingthickness of 0.014 inches, exhibited 0.014 inches of wear depth in abouthalf the time (a little more than eight hours) of Sample H (at littlemore than sixteen hours), tested at an impingement angle of 30 degreesand having a chemical-resistant coating of 0.014 inches thick.

For the stainless steel 17-4 PH often used in flow ends, fifteen testswere performed with the test samples, including eight test samples(i.e., Samples O, P, S, T, W, X, AA, and BB) coated with a coatingcomposition consistent with at least some examples described herein andseven uncoated (bare) test samples. In addition, four of the testsamples were subjected to the relatively larger 100 mesh sand (i.e.,Samples P, T, X, and BB), and four test samples were subjected to therelatively smaller 270 mesh sand (i.e., Samples O, S, W, and AA).Samples M through P were tested at an impingement angle of 0°. Samples Qthrough T were tested at an impingement angle of 30°. Samples U and Xwere tested at an impingement angle of 45°, and Samples Y and BB weretested at an impingement angle of 60°. The results of the tests areprovided in Table 5 below, showing the cumulative mass loss (grams (g))and cumulative wear depth (inches (in)) as a function of the time duringwhich the samples were subjected to the testing. FIG. 11 is a graph ofcumulative wear depth (inches (in)) versus testing time (hours (hr))during which the samples were subjected to the testing for the testresults shown in Table 5.

TABLE 5 Jet Angle Duration Mass loss Wear depth Sample Coated/Bare SandSize (degrees) (hours) (g) (in) M Bare 270 mesh 0 4 1.07 0.040 8 1.820.066 12 2.66 0.093 16 3.34 0.116 N Bare 100 mesh 0 4 0.79 0.045 8 1.380.068 12 2.04 0.089 16 2.56 0.105 O Coated 270 mesh 0 4 0.00 0.000(0.014 in) 8 0.17 0.000 12 1.15 0.031 16 1.94 0.054 P Coated 100 mesh 04 0.00 0.003 (0.014 in) 8 0.01 0.004 12 0.29 0.020 16 0.89 0.041 Q Bare270 mesh 30 4 0.74 0.037 8 1.33 0.062 12 1.99 0.084 16 2.53 0.103 R Bare100 mesh 30 4 0.48 0.026 8 0.97 0.048 12 1.42 0.066 16 1.85 0.083 202.28 0.097 30 24 2.66 0.109 28 3.08 0.121 S Coated 270 mesh 30 4 0.000.000 (0.014 in) 8 0.01 0.000 12 0.49 0.029 16 0.90 0.047 T Coated 100mesh 30 4 0 0.003 (0.014 in) 8 0 0.004 12 0.02 0.005 16 0.02 0.006 200.03 0.008 24 0.37 0.036 28 0.74 0.050 U Bare 270 mesh 45 4 0.67 0.034 81.42 0.066 12 1.96 0.084 16 — — V Bare 100 mesh 45 4 0.48 0.026 8 0.910.047 12 1.39 0.066 16 1.80 0.081 20 2.22 0.095 24 2.65 0.109 W Coated270 mesh 45 4 0.01 0.000 (0.014 in) 8 0.18 0.013 12 0.77 0.050 16 — — XCoated 100 mesh 45 4 0 0.003 (0.014 in) 8 0 0.004 12 0.01 0.005 X(cont.) Coated 100 mesh 45 16 0.01 0.008 20 0.05 0.011 24 0.48 0.042 YBare 270 mesh 60 4 0.79 0.045 8 1.38 0.068 12 2.04 0.089 16 2.56 0.105 ZBare 100 mesh 60 4 0.50 0.029 8 0.98 0.051 12 1.41 0.068 16 1.87 0.08420 2.30 0.098 24 2.73 0.110 28 3.13 0.122 AA Coated 270 mesh 60 4 0.000.000 (0.014 in) 8 0.01 0.000 12 0.29 0.021 16 0.79 0.054 BB Coated 100mesh 60 4 0 0.003 (0.014 in) 8 0 0.004 12 0 0.004 16 0.01 0.005 20 0.010.007 24 0.130 0.023 28 0.560 0.051

As shown in FIG. 11, for the stainless steel 17-4 PH consistent withmaterial typically used in fluid ends, the cumulative wear depth for theeach of the uncoated (bare) testing samples, regardless of impingementangle, was significantly greater as compared to the cumulative weardepth for the coated test samples, regardless of the sand size (i.e.,the relatively larger 100 mesh sand or the relatively smaller 270 meshsand). For example, the worst performing coated sample, Sample W, tookthree times longer to reach a wear depth of 0.014 inches as compared thebest performing uncoated sample, Sample V. The best performing coatedsamples, Samples R, T, and X, took from ten to eleven times longer toreach a wear depth of 0.014 inches. FIG. 11 also shows that generallyall of the samples, both uncoated and coated, exhibited better wear(i.e., slower wear rates) when exposed to the relatively larger sand(the 100 mesh sand) than the relatively smaller sand (the 270 meshsand). (The thicker lines in FIG. 11 show the data for the relativelysmaller sand).

In addition, as shown in Table 5, the cumulative mass loss for the eachof the uncoated testing samples, regardless of impingement angle, wassignificantly greater as compared to the cumulative mass loss for thecoated test samples, regardless of the sand size. The coated testsamples do not show any significant wear depth or mass loss prior to twohours of testing (i.e., about 400 pounds of sand passed), and for anangle of 60°, no significant mass loss occurs until four hours oftesting (i.e., about 800 pounds of sand have passed). (The test sampleswere subjected to approximately 200 pounds of sand erodent for everyfour hours of testing.) As would generally be expected, the amount ofmass loss decreases with the angle of impingement, for example, suchthat the mass loss at 60° is significantly less than for 0° at a giventesting time or passage of sand. In addition, as shown in FIG. 11, thebare samples (Samples M, N, Q, R, U, V, and Z) all reach a wear depth of0.014 inches in two hours or less of testing. In contrast, coated SampleW, which exhibited the quickest wear rate of the coated samples, onlyreached a wear depth of 0.014 inches after six hours of testing, athree-fold decrease in wear rate. The results of the testing suggestthat the tested primer layer and coating layer may significantlyincrease the service life of a fluid handling component for an oilfieldoperation, such as a fluid end associated with a fracturing system.

For the AISI 4715 alloy steel often used in frac iron, eight tests wereperformed with the test samples, including four test samples (i.e.,Samples DD, FF, HH, and JJ) coated with a 0.014-inch thick coatinglayer, including a coating composition consistent with at least someexamples described herein, and four bare (uncoated) test samples.Samples CC and DD were tested at an impingement angle of 0°. Samples EEand FF were tested at an impingement angle of 30°. Samples GG and HHwere tested at an impingement angle of 45°, and Samples II and JJ weretested at an impingement angle of 60°. The results of the tests areprovided in Table 6 below, showing the cumulative mass loss (grams (g))and cumulative wear depth (inches (in)) as a function of the time duringwhich the Samples were subjected to the testing. FIG. 12 is a graph ofcumulative wear depth (inches (in)) versus testing time (hours (hr))during which the Samples were subjected to the testing for the testresults shown in Table 6.

TABLE 6 Coating/ Jet Angle Duration Mass Loss Wear Sample Bare (degrees)(hours) (g) Depth (in) CC Bare 0 4 0.56 0.027 8 1.13 0.056 12 1.59 0.07816 — — DD Coated 0 4 0.00 0.000 (0.014 in) 8 0.32 0.009 12 0.87 0.034 16— — EE Bare 30 4 0.52 0.027 8 0.91 0.050 12 1.38 0.071 16 1.78 0.091 FFCoated 30 4 0.00 0.000 (0.014 in) 8 0.01 0.000 12 0.37 0.032 16 0.740.050 GG Bare 45 4 0.44 0.025 8 0.76 0.042 12 1.17 0.063 16 1.49 0.07820 1.91 0.097 24 2.22 0.108 HH Coated 45 4 0.00 0.000 (0.014 in) 8 0.000.000 12 0.00 0.000 16 0.00 0.000 20 0.26 0.027 24 0.52 0.048 II Bare 604 0.36 0.013 8 0.80 0.44 12 1.11 0.059 16 — — JJ Coated 60 4 0.00 0.000(0.014 in) 8 0.00 0.000 12 0.00 0.000 16 0.06 0.000 20 0.44 0.028

As shown in FIG. 12, for the AISI 4715 alloy steel, which is consistentwith material typically used in frac iron, the cumulative wear depth forthe each of the uncoated (bare) testing samples, regardless ofimpingement angle, was significantly greater as compared to thecumulative wear depth for the coated test samples. For example, theworst performing coated sample, Sample DD having an impingement angle of0 degrees, took three times longer to reach a wear depth of 0.014 inchesas compared uncoated Sample CC having an impingement angle of 0 degrees.The best performing coated samples, Samples FF, HH, and JJ, took fromfour to eight times longer to reach a wear depth of 0.014 inches thanthe uncoated samples.

In addition, as shown in Table 6, the cumulative mass loss for the eachof the uncoated testing samples, regardless of impingement angle, wassignificantly greater as compared to the cumulative mass loss for thecoated test samples. As shown in FIG. 12, the coated test samples do notshow any significant wear depth (or mass loss) prior to two hours oftesting (i.e., about 400 pounds of sand passed), and for an angle of60°, no significant mass loss occurs until after sixteen hours oftesting (i.e., about 800 pounds of sand have passed). (The test sampleswere subjected to approximately 200 pounds of sand erodent for everyfour hours of testing.) In addition, as shown in FIG. 8, the baresamples (Samples CC, EE, GG, and II) all reach a wear depth of 0.014inches in two to four hours of testing. In contrast, coated Sample DD,which exhibited the fastest wear rate of the coated samples, onlyreached a wear depth of 0.014 inches after six hours of testing. Theresults of the testing suggest the tested primer layer and coating layermay significantly increase the service life of a fluid handlingcomponent for an oilfield operation, such as a frac iron componentassociated with a fracturing system.

FIG. 13 is a graph of cumulative mass loss (grams (g)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at animpingement angle of zero degrees according to the disclosure. As shownin FIG. 13, while the uncoated (bare) samples (Samples A, M, and Ccorresponding respectively to the goat head, the fluid end, and the fraciron) begin losing mass almost immediately during testing, the coatedsamples (Samples B, O, and DD corresponding respectively to the goathead, the fluid end, and the frac iron) do not begin to lose mass untilafter four of testing, and Sample B does not begin to lose mass untilafter eight hours of testing.

FIG. 14 is a graph of cumulative mass loss (grams (g)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at animpingement angle of thirty degrees according to the disclosure. Asshown in FIG. 14, the uncoated (bare) samples (Samples E, Q, and EEcorresponding respectively to the goat head, the fluid end, and the fraciron) begin losing mass almost immediately during testing. In contrast,the coated samples (Samples F, S, and FF corresponding respectively tothe goat head, the fluid end, and the frac iron) do not begin to losemass until after eight of testing.

FIG. 15 is a graph of cumulative mass loss (grams (g)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at animpingement angle of 45 degrees according to the disclosure. As shown inFIG. 15, the uncoated (bare) samples (Samples I, U, and GG correspondingrespectively to the goat head, the fluid end, and the frac iron) beginlosing mass almost immediately during testing. In contrast, the coatedsamples (Samples J, W, and HH corresponding respectively to the goathead, the fluid end, and the frac iron) do not begin to lose mass untilafter eight, four, and sixteen hours of testing, respectively.

FIG. 16 is a graph of cumulative mass loss (grams (g)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at animpingement angle of sixty degrees according to the disclosure. As shownin FIG. 16, the uncoated (bare) samples (Samples K, Y, and IIcorresponding respectively to the goat head, the fluid end, and the fraciron) begin losing mass almost immediately during testing. In contrast,the coated samples (Samples L, AA, and JJ corresponding respectively tothe goat head, the fluid end, and the frac iron) do not begin to losemass until after sixteen, eight, and sixteen hours of testing,respectively.

FIG. 17 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at animpingement angle of zero degrees according to the disclosure. As shownin FIG. 17, the uncoated (bare) samples (Samples A, M, and CCcorresponding respectively to the goat head, the fluid end, and the fraciron) reach a wear depth of 0.014 inches within two hours or less of thestart of testing. In contrast, the coated samples (Samples BB, O, and DDcorresponding respectively to the goat head, the fluid end, and the fraciron) do not reach a wear depth of 0.014 inches until after ten hours,eight and one-half hours, and six and one-half hours of testing,respectively.

FIG. 18 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at animpingement angle of thirty degrees according to the disclosure. Asshown in FIG. 18, the uncoated (bare) samples (Samples E, Q, and EEcorresponding respectively to the goat head, the fluid end, and the fraciron) reach a wear depth of 0.014 inches within two hours or less of thestart of testing. In contrast, the coated samples (Samples F, S, and FFcorresponding respectively to the goat head, the fluid end, and the fraciron) do not reach a wear depth of 0.014 inches until after about ninehours of testing, which represents a more than four-fold reduction inwear rate.

FIG. 19 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at animpingement angle of forty-five degrees according to the disclosure. Asshown in FIG. 19, the uncoated (bare) samples (Samples I, U, and GGcorresponding respectively to the goat head, the fluid end, and the fraciron) reach a wear depth of 0.014 inches within about two hours or lessof the start of testing. In contrast, the coated samples (Samples J, W,and HH corresponding respectively to the goat head, the fluid end, andthe frac iron) do not reach a wear depth of 0.014 inches until afterabout six hours, nine and one-half hours, and about seventeen hours oftesting, respectively.

FIG. 20 is a graph of cumulative wear depth (inches (in)) versus time(hours (hr)) of exposure to the test fluid flow of test results fromtesting uncoated (bare) test samples and coated test samples simulatinggoat heads, fluid ends, and frac iron exposed to fluid flow at animpingement angle of sixty degrees according to the disclosure. As shownin FIG. 20, the uncoated (bare) samples (Samples K, Y, and IIcorresponding respectively to the goat head, the fluid end, and the fraciron) reach a wear depth of 0.014 inches within about one and one-halfhours (Samples K and Y) or within about four hours (Sample II) of thestart of testing. In contrast, the coated samples (Samples L, AA, and JJcorresponding respectively to the goat head, the fluid end, and the fraciron) do not reach a wear depth of 0.014 inches until after aboutseventeen hours, about nine and one-half hours, and about sixteen andone-half hours of testing, respectively.

FIG. 21 is a bar graph showing estimated hours to 0.014 inches of weardepth for uncoated (bare) samples and coated samples simulating goatheads, fluid ends, and frac iron exposed to fluid flow at differentimpingement angles and for each of two sand sizes (the relativelysmaller 270 mesh sand and the relatively larger 100 mesh sand) accordingto the disclosure. In addition, FIG. 21 also shows example comparisonfactors. For example, the comparison factors may be indicative of afirst amount of time during which the coating wears to a first depthdivided by a second amount of time during which the fluid handlingcomponent without the coating wears to the first depth. For example, thecomparison factor may be indicative of the level of wear improvementprovided to each of the test samples by a 0.014-inch thick coatinglayer, including a coating composition consistent with at least someexamples described herein relative to the uncoated test samples.

As shown in FIGS. 10-20, graphs of both wear depth and mass loss for thetest samples show very similar slopes after the coating layer ispenetrated and sand particles begin impacting the bare metal underneath.For the purpose of comparing the relative wear-resistance performance ofthe uncoated and coated test samples, the time to break through thecoating layer was estimated in one of two ways. First, the estimatedtime for breakthrough was estimated using mass loss data. The slope ofmass loss for an initial four-hour window was determined for theuncoated metal. For coated samples, measurable mass loss was negligibleuntil breakthrough occurred. After this point in time, the next massmeasurement at the four-hour interval was significantly larger, and thebreakthrough was visually observed during an inspection. The uncoatedtest sample slope was used to extrapolate backward from the first pointafter breakthrough to find an x-intercept point on the graph, and thetime corresponding to the x-intercept point was identified to representthe approximate time of breakthrough based on mass loss. Second, theestimated time for breakthrough was estimated using wear depth data. Thewear depth for the test samples was measured. Before coatingbreakthrough, the wear depth was indicative of a loss in coatingthickness (0.014 inches), which is shown in FIGS. 10-12 and 17-20. Theslope on the graphs of the uncoated test samples was used to extrapolatebackward from the measured wear depth on the graph after breakthrough ofthe coating layer to estimate the intercept point at which the weardepth equaled 0.014 inches (e.g., see the horizontal line on the graphsof FIGS. 10-12 and 17-20). The time corresponding to the intercept pointwas used as the estimated time of breakthrough of the coating layerbased on wear depth. If the estimated breakthrough time calculated basedon mass loss differed from the estimated breakthrough time calculatedbased on wear depth for a given test sample, the two values wereaveraged to determine a single breakthrough time for the test sample.

After the breakthrough times were calculated for each of the coatedsamples, a relative erosion-resistance between the coated and uncoatedsamples was calculated. A linear interpolation was performed along theuncoated test sample wear depth line to calculate a time to wear through0.014 inches of the uncoated metal test samples. To determine acomparison factor for the coating, the breakthrough time of the coatinglayer was divided by the time to reach a wear depth of 0.014 inches forthe corresponding uncoated test sample. As shown in FIG. 21, thecomparison factors range from about 3.0 to about 17.5, which isindicative of the level of wear-resistance improvement provided by thecoating layers.

For example, as shown in FIG. 21, for the simulated goat head material,at an impingement angle of zero degrees and with the 270 mesh sand,compared to the uncoated test sample, it took the coated test sample 7.1times longer to reach a wear depth of 0.014 inches (e.g., the comparisonfactor corresponding to 7.1). In another example, as shown in FIG. 21,for the simulated goat head material, at an impingement angle offorty-five degrees and with the 100 mesh sand, compared to the uncoatedtest sample, it took the coated test sample 17.0 times longer to reach awear depth of 0.014 inches (e.g., the comparison factor corresponding to17.0). For the simulated fluid end material, at an impingement angle ofzero degrees and with the 270 mesh sand, compared to the uncoated testsample, it took the coated test sample 5.5 times longer to reach a weardepth of 0.014 inches (e.g., the comparison factor corresponding to5.5). In another example, as shown in FIG. 21, for the simulated fluidend material, at an impingement angle of sixty degrees and with the 100mesh sand, compared to the uncoated test sample, it took the coated testsample 11.8 times longer to reach a wear depth of 0.014 inches (e.g.,the comparison factor corresponding to 11.8). For the simulated fraciron material, at an impingement angle of forty-five degrees and withthe 100 mesh sand, compared to the uncoated test sample, it took thecoated test sample 17.2 times longer to reach a wear depth of 0.014inches (e.g., the comparison factor corresponding to 17.2). With theexample comparison factors ranging from a minimum of about 3.0 to amaximum of about 17.5, the coating layer exhibits significantimprovement in wear-resistance of the test samples.

FIG. 22 is a bar graph showing estimated hours to 0.014 inches of weardepth for a simulated goat head material for bare samples, sampleshaving 0.014 inches of depth of coating (“coated”), samples having 0.028inches of depth of coating (“thick-coated”), and samples coated with achemical-resistant coating (“chem. resistant”), simulating goat headsexposed to fluid flow at zero and thirty degrees and for each of twosand sizes (270 mesh and larger 100 mesh) according to the disclosure.FIG. 22 also shows comparison factors for each of the test samples in amanner similar to FIG. 21. For example, at an impingement angle of zerodegrees and with the 270 mesh sand, compared to the uncoated testsample, it took the coated test sample 7.1 times longer to reach a weardepth of 0.014 inches (e.g., the comparison factor corresponding to7.1). At an impingement angle of zero degrees and with the 270 meshsand, compared to the uncoated test sample, it took the thick-coatedtest sample 8.8 times longer to reach a wear depth of 0.014 inches(e.g., the comparison factor corresponding to 8.8). At an impingementangle of zero degrees and with the 270 mesh sand, compared to theuncoated test sample, it took the chemical-resistant coated test sample12.3 times longer to reach a wear depth of 0.014 inches (e.g., thecomparison factor corresponding to 12.3). At an impingement angle ofzero degrees and with the 100 mesh sand, compared to the uncoated testsample, it took the chemical-resistant coated test sample 10.6 timeslonger to reach a wear depth of 0.014 inches (e.g., the comparisonfactor corresponding to 10.6). At an impingement angle of thirty degreesand with the 100 mesh sand, compared to the uncoated test sample, ittook the chemical-resistant coated test sample 28.2 times longer toreach a wear depth of 0.014 inches (e.g., the comparison factorcorresponding to 28.2). As shown in FIG. 22, the comparison factorsrange from a minimum of about 6.0 to a maximum of about 28.5, thecoating layers exhibit significant improvements in wear-resistance ofthe test samples.

Oilfield components, such as fluid ends, are sometimes formed fromcarbon steel, and more recently, some manufacturers of fluid ends haveswitched to stainless steel, which may in some instances provide alonger service life as compared to fluid ends formed from carbon steel.Sometimes, a fluid end formed from stainless steel may have up to twicethe service life as compared to a comparable fluid end formed fromcarbon steel. Stainless steel historically tends to be more expensivethan carbon steel, sometimes as much as twice as expensive. Coatingcompositions, coating layers, and/or related methods consistent with atleast some of those described herein may be capable of being used withoilfield components (e.g., fluid ends) formed from carbon steel toachieve service lives approaching or exceeding those for comparableoilfield components formed from stainless steel. Thus, at least someexamples described herein may be able to reduce expenses associated withpurchase, maintenance, production downtime, and/or replacement costsassociated with oilfield components and oilfield operations.

Having now described some illustrative embodiments of the disclosure, itshould be apparent to those skilled in the art that the foregoing ismerely illustrative and not limiting, having been presented by way ofexample only. Numerous modifications and other embodiments are withinthe scope of one of ordinary skill in the art and are contemplated asfalling within the scope of the disclosure. In particular, although manyof the examples presented herein involve specific combinations of methodacts or system elements, it should be understood that those acts andthose elements may be combined in other ways to accomplish the sameobjectives. Those skilled in the art should appreciate that theparameters and configurations described herein are exemplary and thatactual parameters and/or configurations will depend on the specificapplication in which the systems, methods, and or aspects or techniquesof the disclosure are used. Those skilled in the art should alsorecognize or be able to ascertain, using no more than routineexperimentation, equivalents to the specific embodiments of thedisclosure. It is, therefore, to be understood that the embodimentsdescribed herein are presented by way of example only and that, withinthe scope of any appended claims and equivalents thereto, the disclosuremay be practiced other than as specifically described.

This is a continuation application of U.S. Non-Provisional applicationSer. No. 17/225,543, filed Apr. 8, 2021, titled “COATED OILFIELDOPERATIONAL COMPONENTS AND METHODS FOR PROTECTING AND EXTENDING THESERVICE LIFE OF OILFIELD OPERATIONAL COMPONENTS,” which claims priorityto and the benefit of, under 35 U.S.C. § 119(e), U.S. ProvisionalApplication No. 63/008,035, filed Apr. 10, 2020, titled “COATINGCOMPOSITIONS, COATED OILFIELD OPERATIONAL COMPONENTS, AND RELATEDMETHODS FOR OILFIELD OPERATIONS,” U.S. Provisional Application No.63/008,038, filed Apr. 10, 2020, titled “METHODS FOR PROTECTING OILFIELDOPERATIONAL COMPONENTS FROM DAMAGE FROM FLUID FLOW,” U.S. ProvisionalApplication No. 63/008,042, filed Apr. 10, 2020, titled “COATING ANDMETHODS FOR EXTENDING SERVICE LIFE OF OILFIELD OPERATIONAL COMPONENTS,”U.S. Provisional Application No. 63/008,046, filed Apr. 10, 2020, titled“METHODS FOR PREPARING COATING COMPOSITIONS FOR PROTECTING OILFIELDOPERATIONAL COMPONENTS,” U.S. Provisional Application No. 63/008,049,filed Apr. 10, 2020, titled “METHODS FOR PROVIDING FLEXIBLE AND/ORELASTIC COATINGS ON OILFIELD OPERATIONAL COMPONENTS,” U.S. ProvisionalApplication No. 63/065,542, filed Aug. 14, 2020, titled “COATED OILFIELDOPERATIONAL COMPONENTS AND METHODS FOR PROTECTING AND EXTENDING THESERVICE LIFE OF OILFIELD OPERATIONAL COMPONENTS,” U.S. ProvisionalApplication No. 63/065,545, filed Aug. 14, 2020, titled “METHODS FORPROTECTING OILFIELD OPERATIONAL COMPONENTS FROM DAMAGE FROM FLUID FLOW,”U.S. Provisional Application No. 63/065,565, filed Aug. 14, 2020, titled“COATING AND METHODS FOR EXTENDING SERVICE LIFE OF OILFIELD OPERATIONALCOMPONENTS,” U.S. Provisional Application No. 63/065,577, filed Aug. 14,2020, titled “METHODS FOR PREPARING COATING COMPOSITIONS FOR PROTECTINGOILFIELD OPERATIONAL COMPONENTS,” U.S. Provisional Application No.63/065,591, filed Aug. 14, 2020, titled “METHODS FOR PROVIDING FLEXIBLEAND/OR ELASTIC COATINGS ON OILFIELD OPERATIONAL COMPONENTS,” and U.S.Provisional Application No. 63/198,044, filed Sep. 25, 2020, titled“COATED OILFIELD OPERATIONAL COMPONENTS AND METHODS FOR PROTECTING ANDEXTENDING THE SERVICE LIFE OF OILFIELD OPERATIONAL COMPONENTS,” thedisclosures of all of which are incorporated herein by reference intheir entireties.

Furthermore, the scope of the present disclosure shall be construed tocover various modifications, combinations, additions, alterations, etc.,above and to the above-described embodiments, which shall be consideredto be within the scope of this disclosure. Accordingly, various featuresand characteristics as discussed herein may be selectively interchangedand applied to other illustrated and non-illustrated embodiment, andnumerous variations, modifications, and additions further may be madethereto without departing from the spirit and scope of the presentdisclosure as set forth in the appended claims.

What is claimed is:
 1. A method for protecting an operational componentexposed to flow of fluid, the method comprising: applying a primercomposition to the operational component; at least partially curing theprimer composition to form a primer layer, such that the primer layer isat least partially mechanically bonded to the operational component;applying a coating composition to the primer layer, the coatingcomposition comprising trifunctional silane, silanol fluid, fillers, andtitanium dioxide; and at least partially curing the coating compositionto form a coating layer, such that the coating layer is at leastpartially chemically bonded to the primer layer to enhance wearresistance of the operational component, the coating compositioncomprising T-resin units each forming one or more bonds with one or moreof other T-resin units, silanol fluid, fillers, or the titanium dioxide,such that the operational component exhibits a comparison factorindicative of an increased resistance to wear greater than about 2, thecomparison factor being indicative of a first amount of time duringwhich a portion of one or more of the coating layer or the primer layerwears to a first depth divided by a second amount of time during which aportion of the operational component without the one or more of thecoating layer or the primer layer wears to a second depth equal to thefirst depth.
 2. The method of claim 1, wherein the coating compositionfurther comprises one or more pigments, and the T-resin units form twoor more bonds with one or more of other T-resin units, silanol fluid,titanium dioxide, or fillers, and the one of more pigments.
 3. Themethod of claim 1, wherein applying the primer composition to theoperational component comprises applying the primer composition to atleast a portion of an oilfield operational component, and wherein thecomparison factor ranges from about 5 to about
 30. 4. The method ofclaim 1, wherein applying the primer composition to the operationalcomponent comprises applying one or more of an aliphatic amine,epichlorohydrin, a bisphenol, silane adhesion promoter,trimethoxysilane, triethoxysilane, or 3-glycidoxypropyltrimethoxysilaneto the operational component.
 5. The method of claim 1, wherein applyingthe coating composition comprises spraying the coating composition ontothe operational component via a spray head configured to atomize thecoating composition as it is applied to the operational component. 6.The method of claim 5, wherein spraying the coating composition onto theoperational component via the spray head comprises: pumping the coatingcomposition via an airless pump at an output ratio ranging from about40:1 to about 80:1 to a spray head configured to rotate and atomize thecoating composition; and supplying air to the spray head to cause thespray head to rotate as the coating composition is atomized and sprayedfrom the spray head.
 7. The method of claim 1, further comprisingapplying the coating composition to the coating layer to form a secondcoating layer and at least partially drying the second coating layer. 8.The method of claim 1, wherein applying the primer composition to theoperational component comprises applying the primer composition to atleast a portion of a fluid end, and the comparison factor ranges fromabout 3 to about
 12. 9. The method of claim 1, wherein applying theprimer composition to the operational component comprises applying theprimer composition to at least a portion of one or more of a goat headcomponent or a frac iron component, and the comparison factor rangesfrom about 2 to about
 20. 10. The method of claim 1, wherein protectingthe operational component exposed to flow of the oilfield fluidcomprises protecting the operational component from exposure to flow ofone or more of water, proppants, or thickening agents.
 11. The method ofclaim 1, further comprising: applying the coating composition to thecoating layer to form a second coating layer and at least partiallydrying the second coating layer; and applying the coating composition tothe second coating layer to form a third coating layer and at leastpartially drying the third coating layer.
 12. A method for protecting anoperational component exposed to fluid flow, the method comprising:spraying a primer composition onto the operational component via a sprayhead configured to atomize the primer composition as it is applied tothe operational component; at least partially curing the primercomposition to form a primer layer, such that the primer layer is atleast partially mechanically bonded to the operational component;spraying a coating composition onto the primer layer, the coatingcomposition comprising trifunctional silane, silanol fluid, fillers, andtitanium dioxide; and at least partially curing the coating compositionto form a coating layer, such that the coating layer is at leastpartially chemically bonded to the primer layer to enhance wearresistance of the operational component, the coating compositioncomprising T-resin units each forming one or more bonds with one or moreof other T-resin units, silanol fluid, fillers, or the titanium dioxide,such that the operational component exhibits a comparison factorindicative of an increased resistance to wear, the comparison factorbeing indicative of a first amount of time during which a portion of oneor more of the coating layer or the primer layer wears to a first depthdivided by a second amount of time during which a portion of theoperational component without the one or more of the coating layer orthe primer layer wears to a second depth equal to the first depth. 13.The method of claim 12, wherein spraying the coating composition ontothe operational component via the spray head comprises: pumping thecoating composition via an airless pump at an output ratio ranging fromabout 40:1 to about 80:1 to a spray head configured to rotate andatomize the coating composition; and supplying air to the spray head tocause the spray head to rotate as the coating composition is atomizedand sprayed from the spray head.
 14. The method of claim 12, furthercomprising spraying the coating composition onto the coating layer toform a second coating layer and at least partially drying the secondcoating layer.
 15. The method of claim 12, wherein spraying the primercomposition onto the operational component comprises spraying one ormore of an aliphatic amine, epichlorohydrin, a bisphenol, silaneadhesion promoter, trimethoxysilane, triethoxysilane, or3-glycidoxypropyltrimethoxysilane onto the operational component. 16.The method of claim 15, wherein the comparison factor ranges from about2 to about
 20. 17. The method of claim 12, wherein the coatingcomposition further comprises one or more pigments, and the T-resinunits form two or more bonds with one or more of other T-resin units,silanol fluid, titanium dioxide, or fillers, and the one of morepigments, and wherein the operational component comprises an oilfieldoperational component.
 18. A method for protecting an operationalcomponent exposed to fluid flow, the method comprising: applying aprimer composition to the operational component; at least partiallycuring the primer composition to form a primer layer, such that theprimer layer is at least partially mechanically bonded to theoperational component; applying a coating composition to the primerlayer, the coating composition comprising trifunctional silane, silanolfluid, fillers, and one or more pigments, the one or more pigmentscomprising one or more blue pigments; and at least partially curing thecoating composition to form a coating layer, such that the coating layeris at least partially chemically bonded to the primer layer to enhancewear resistance of the operational component, the coating compositioncomprising T-resin units each forming one or more bonds with one or moreof other T-resin units, silanol fluid, fillers, or the one or morepigments, such that the operational component exhibits a comparisonfactor indicative of an increased resistance to wear greater than about2, the comparison factor being indicative of a first amount of timeduring which a portion of one or more of the coating layer or the primerlayer wears to a first depth divided by a second amount of time duringwhich a portion of the operational component without the one or more ofthe coating layer or the primer layer wears to a second depth equal tothe first depth.
 19. A method for protecting an operational componentexposed to fluid flow, the method comprising: spraying a primercomposition onto the operational component via a spray head configuredto atomize the primer composition as it is applied to the operationalcomponent; at least partially curing the primer composition to form aprimer layer, such that the primer layer is at least partiallymechanically bonded to the operational component; spraying a coatingcomposition onto the primer layer, the coating composition comprisingtrifunctional silane, silanol fluid, fillers, and one or more pigments,the one or more pigments comprising one or more blue pigments; and atleast partially curing the coating composition to form a coating layer,such that the coating layer is at least partially chemically bonded tothe primer layer to enhance wear resistance of the operationalcomponent, the coating composition comprising T-resin units each formingone or more bonds with one or more of other T-resin units, silanolfluid, fillers, or the one or more pigments, such that the operationalcomponent exhibits a comparison factor indicative of an increasedresistance to wear, the comparison factor being indicative of a firstamount of time during which a portion of one or more of the coatinglayer or the primer layer wears to a first depth divided by a secondamount of time during which a portion of the operational componentwithout the one or more of the coating layer or the primer layer wearsto a second depth equal to the first depth.